1990 Ford Truck Emmisions Manual

Important Safety Notice
APpropriate service methods and proper repair procedures are essential

fOr the safe, reliable operation Of all motor vehicles as well as the per-
sonal safety of the Individual doing the work. This Shop Manual provides
general directions fOr accomplishing service and repair work with tested,
effective techniQues. Following them will help assure reliability.
There are numerous variations In procedures. techniques. tOOlS. and
parts fOr servicing vehicles. as well as In the skill of the Individual doing
the work. This Manual cannot possibly anticipate all such variations and
provide advice or cautions as to each. Accordingly. anyone who departs
from the Instructions provided In this Manual must first establish that he
compromises neither his personal safety nor the vehicle Integrity by his
Choice Of methods, tools or parts.
Notes, cautions, and warnings

AS you read through the procedures, you will come across NOTES. CAU-
TIONS. and WARNINGS. Each one Is there fOr a specific purpose. NOTES give
you added InfOrmation that will help you to complete a particular proce-
dure. CAUTIONS are given to prevent you from making an error that could
damage the vehicle. WARNINGS remind you to be especially careful In
those areas where carelessness can cause personal Injury. The fOllowing
list contains some general WARNINGS that you should follow when you
work on a vehicle.
Always wear safety glasses for eye protection.
use safety stands whenever a procedure reQuires you to be under the
vehIcle.
Be sure that the Ignition switch Is always In the OFF position, unless
otherwise required by the procedure.
Set the parking brake when working on the vehicle. If you have an
automatic transmission, set It In PARK unless Instructed otherwise for a
specific operation. If you have a manual transmission. It should be In
REVERSE (engine OFF) or NEUTRAL (engine ON) unless Instructed other-
wise for a specific operation. Place wood blocks (4" x 4" or larger) to
the front and rear surfaces of the tires to provide further restraint
from Inadvertent vehicle movement.
Operate the engine only In a well-ventilated area to avoid the danger
Of carbon monoxide.
Keep yourself and your clothing away from moving parts. when the
engine Is running, especially the fan and belts.
TO prevent serious bu,-ns, avoid contact With hot metal parts such as
the radiator. exhaust manifOld, tall pipe. catalytic converter and mUf-
fler.
Do not smoke while working on a vehicle.
TO avoid Injury. always remove rings. watches, loose hanging jewelry,
and loose clothing before beginning to work on ,a vehicle.
Keep hands and other objects clear of the radiator fan blades. The elec-
tric cooling fan on the Escort can start to operate at any time by an
Increase In underhood temperature, even though the Ignition Is In the
OFF position. Other vehicles With an electric cooling fan can start at
any time for the same reason, but only when the Ignition switch Is In
the RUN position. Therefore, care should be taken to ensure that the
electric cooling fan motor Is completely disconnected when working
under the hood.
DAVE GRAHAM INC. 2012

ALL RIGHTS RESERVED
Foreword
This 1990 Car Shop Manual provides information covering Emissions for
all 1990 Ford Motor Company Passenger Cars and Trucks manufactured
in the United States and Canada. Complete emissions related diagnostic
procedures for all affected systems or components are covered in this
manual.
The descriptions and specifications contained in this manual were in
effect at the time this manual was approved for printing. Ford Motor
Company reserves the right to discontinue models at any time, or
change specifications or design without notice and without incurring
obligation.
For service information on specific vehicle lines for Body, Chassis and
Electrical; powertrains; and / or Pre-Delivery and Lubrication, refer to the
Passenger Car and Truck Cross Index pages in the front of this manual.
~trbict
~ublication5
Ford Parts and Service Division
Copyright 1989, Ford Motor Company

ALL RIGHTS RESERVED
passenger Car
Cross Reference Index
vehicle Lines content
Lincoln TOwn car, Crown Victoria / Body, Chassis, Electrical, POwertraln,
Orand Marauls Maintenance, Lubrication
Mark VII Body, Chassis, Electrical, POwertraln,

Maintenance, Lubrication
Thunderbird I Cougar Body, Chassis, "Electrical, POwertraln,

Mustang Body, Chassis, Electrical, Powertrain,

Tempo I Topaz, Escort Body, Chassis, Electrical, Powertrain,

Taurus/Sable Body, Chassis, Electrical, Powertraln,

Continental Body, Chassis, Electrical, Powertraln,

All Models pre-Delivery
NAAO car & Truck Models Engine / Emissions Diagnosis
Non-NAAO Cars Non-NAAO Engine I Emissions Diagnosis

ALL RIGHTS RESERVED
Truck
Cross Reference Index
vehicle Lines content
Econollne, F-serles, Bronco BOdY/ Chassis / Electrical
Econonne, F-Serles, Bronco Engine
Medium/Heavy Duty B-, C, F-600 Body / Chassis / Electrical! Engine

Through 8000 Series
Aerostar, Ranger, Bronco II (1 Of 2) Engine / Chassis
Aerostar. Ranger, Bronco II (2 Of 2) BOdy/ Electrical
All Truck Series and car Models pre-Delivery (Volume F)
All NAAO car and Truck Models Engine / Emissions Diagnosis

ALL RIGHTS RESERVED
What's New
In This Manual
The fOllowing is a list of the modifications to this manual fOr 1990.
New or Modified Applications
1990 1/2 1.9L SEFI MA Escort/Tracer (EDIS Ignition)
2.3L EFI MA CalifOrnia - Mustang
2.9L EFI Scorpio
2.9L EFI MA Ranger / Bronco II
3.0L EFI probe
4.0L EFI MA Ranger / Bronco III Aerostar (EDIS Ignition)
4.9L EFI Truck with Electronically Controlled (E40D)
Transmission
S.OL SEFI MA California - LIncoln Town car, Crown
Victoria / Orand Marquis (Sedan)
Modified Manual sections

A Diagnostic Flowchart has been added to "How to Use This
Manual"
Diagnostic Routines, Section 2, has added On-line Automatic
Service Information System (OASIS) reference numbers
Fuel Delivery Systems, Section 11, has added an In Tank
Reservoir UTR) fuel delivery system
Ignition Systems, Timing procedures and Diagnosis, Section
13, has added Electronic Dlstrlbutorless Ignition Systems (EDIS)
EEC-IV Monitor BOX: Intermittent Fault Diagnosis, Section 18,
Is Included as a part of this manual
~ew or Modified Pinpoint Tests

AA has been added to diagnose "NO Starts" on EDIS
applications
DA has been revised to cover all 2-wlre temperature sensors
(ACT, ECT, and VAT)
DR has been added to diagnose the Cylinder Identification
(CID) sensor on 19901/2 1.9L SEFI MA Escort/Tracer
applications
H has been revised to Include 4-wlre HEOO sensors
KF has been added to diagnose the Electrodrlve Fan (EDF)
control on 19901/2 1.9L SEFI MA Escort/Tracer applications
KH has been added for Service Pin adjustment on 2.9L EFI
Scorpio applications
Nand P have been revised to Include EDIS applications

ALL RIGHTS RESERVED
Table of contents
section Title section Number
How to use This Manual .1
GlOssary 11
Emissions control Identification / Application 1
Diagnostic Routines 2
Emission Related components 3
Carburetors, Throttle Bodies, and Injectors 4
Catalyst and Exhaust Systems 5
Exhaust Gas Recirculation (EGR) Systems 6
Evaporative Emission Systems 7
Inlet Air Temperature Systems 8
positive crankcase ventilation (PCV) Systems 9
Thermactor Systems (Secondary Air InJection) 10
Fuel Delivery Systems 11
6.1L/7.0L Heavy DUty Truck "CHECK ENGINE" LIght 12
Ignition System, Timing Procedures and Diagnosis 13
How to Use Oulck Test .III
EEC-IV Oulck Test Procedures and Appendix 14
EEC-IV Engine Supplement-passenger Car 15
EEC-IV Engine Supplement-Light Truck 16
EEC-IV Pinpoint Test Procedures 17
EEC-IV Monitor Box: Intermittent Fault Diagnosis 18
Diesel Dlagnosls-6.6L and 7.8L Engines 19
Diesel Dlagn~sls-7 .3L Englne 20

ALL RIGHTS RESERVED
How TO use This Manual
Special Notes:
This,manual is designed to diagnose gasoline and diesel
engine systems.
In each case, begin diagnosis with Section 2, Diagnostic
Routines. Section 2 defines the probable causes of the
vehicle's symptoms. It functions as a checklist to ensure
that all potential causes are reviewed.
If a diagnostic procedure does not find the solution to
a vehicle symptom, it is important to return to Section
2 to review all other possible causes of the symptom.
Refer to Section 3 for component descriptions and part
numbers.
Component locations can be found in the Electrical and
Vacuum Trouble-Shooting Manuals (EVTM's).
The EEC-IV Diagnostics Sections are interrelated and
should be used in conjunction with each other.
Refer to Section 1, Emission Control

Identification / Application, to identify the emission
components on the vehicle. For vehicles with diesel
engines, refer to Sections 19 and 20.
Begin diagnosis with the Diagnostic Routines in Section
2.
Read all special notes.
Prevent any unsafe or hazardous conditions by
following the notes, cautions and warnings listed at the
beginning of this book.
After service, always verify that the repair corrected
the customer complaint.
IDon't I
Skip from Section to Section.

ALL RIGHTS RESERVED
1990 Engine I Emissions Diagnosis
Manual Flowchart
I SYMPTOM)
SECTION 2
"Diagnostic Routines" 1-----41.1 Other Shop I----~.I Verify
t----------.~--- - ----- Manuals Repair
List of Probable
Causes
+
I
I
I
I
SECTIONS 3, 4, 5, 6, 7, COMPLEMENTARY INFORMATION

8, 9, 10, 11, 12, 13, 14,
17, 18, 19, 20 In Engine/Emissions
Diagnosis Manual:
Diagnostics for:
- EEC-IV Systems - SECTION 1: Emissions
- Emissions Related Control Identificationl
Systems Application
- Diesel Systems - SECTION 15: Engine
Supplement-Passenger
Car*
- SECTION 16: Engine
, Supplement-Light
I Verify Repair 1 Truck*
Outside Engine/Emissions
Diagnosis Manual:
- Electrical and Vacuum

rrouble-Shooting Manuals
(EVTM's)
- OASIS Messages
- Technical Service
Bulletins (TSB's)
* Includes: -Schematics
-Service Code Definitions
- Pin Usage Charts
-Sensor/Actuator Reference
Value Charts

ALL RIGHTS RESERVED
Glossary
Contents
Glossary 1

ALL RIGHTS RESERVED
Glossary 1
Glossary
The glossary is a list of technical terms or acronyms and their definitions. It is not intended to
be a dictionary of components and their functions. If you desire a detailed description of a
specific component, refer to the related Shop Manual Group.
4EAT: 4-Speed Electronic Automatic ATDC: After Top Dead Center.

Transaxle.
AVOM: Analog Volt-Ohm Meter.
4X4l: 4X4 Low input switch.
AXOD: Automatic Transaxle Overdrive.
A4lD: Automatic 4-Speed Lock-up-converter
Drive. AXODE: Automatic Transaxle Overdrive,
Electronically Controlled.
A/C: Air Conditioning.
BASE IDLE: Idle RPM determined by
ACC: AIC Clutch Compressor signal input throttle lever hardset on throttle body while
to the EEC-IV processor relating status of Idle Speed Control is fully retracted and
the AIC clutch. disconnected. .
ACCS: AIC Cycling Switch. BATT: Battery
AIC P: AIC Pressure Cut-out switch. BATT( +): Battery positive post or its circuit.
AIC DV: Air Cleaner Duct and Valve BATT( -): Battery negative post or its
motor. circuit.
ACl: Automatic Adjustable Shock BOB: (Breakout Box) An EEC-IV test

Controller. device which connects in series with the
processor and the EEC-IV harness and
A/Cl BIMET: Air Cleaner Bimetal sensor. permits measurements of processor inputs
and outputs.
ACD: Air Conditioner Demand switch.
BOO: Brake On-Off input to the EEC-IV
ACT: Air Charge Temperature sensor or its processor. indicating a braking drive mode.
signal circuit.
BP: Barometric Pressure sensor or its
ACV: (Thermactor) Air Control Valve. signal circuit.
AHFSS: Air Condition/Heater Function BPA: By-Pass Air Solenoid. Used to control
Select Switch input to the EEC-IV idle speed on EFI and SEFI vehicles.
processor relating status of the AIC heater
function select switch. BREAKOUT BOX: A service tool that
"tees" in-between the EEC-IV processor
AIR BPV: (Thermactor) Air Bypass Valve. and the 60-pin harness connector. The
breakout box contains 60 test pins that can
AM1: Thermactor Air Management.1 (TAB). be probed for EEC-IV testing.
AM2: Thermactor Air Management 2 (TAD). BTDC: B.ef.ore Top Dead Center.
AMBIENT TEMPERATURE: Temperature of BV: Bowl Vent (Carburetor Fuel Bowl)
air surrounding an object e.g., temperature
where vehicle is being worked on. BVT: Back Pressure Variable Transducer.
AOD: Automatic Overdrive. CANP: Canister Purge solenoid or its

con'trol circuit.
ANTIBFV: Anti-Backfire Valve.
CSE GND: Case Ground (EEC-IV processor
A/T: Automatic Transmission. case).

ALL RIGHTS RESERVED
2 Glossary
Glossary
CATALYST: A muffler-like device in the CURB IDLE: Computer controlled Idle rpm.
exhaust system containing a monolithic
substrate (a ceramic honeycomb structure) CWM: Cold Weather Modulator.
that is coated with catalytic metals such as
DCl: Data Communications Link.
platinum or palladium. When hot exhaust
gases come in contact with these metals a DFS: Decel Fuel Shut-off.
chemical reaction takes place to consume
unburned hydrocarbon, carbon monoxide DIS: Distributorless Ignition System (low
and nitrous oxides. data rate).
CBD: Closed Bowl Distributor. With this DOL: Data Output Link. Fuel calculation
design, the TFI-IV module is electrically data from the EEC-IV processor to the
connected to the distributor thru a harness electronic tripminder.
connector, not a direct plug in connection.
DPDIS: Dual Plug Distributorless Ignition
CCC: Converter Clutch Control solenoid or System.
its control circuit.
DPH: Dual Plug Head.
CCD: Computer Controlled Dwell.
DPI: Dual Plug Inhibit.
CCO: Converter Clutch Override output
from the EEC-IV processor to the DV: Delay Valve.
transmission.
DVOM: Digital Volt-Ohm Multimeter that
CCS: Coast Clutch Solenoid or its control displays voltage or resistance
circuit. measurements in digital form on a liquid
CES: Clutch Engage Switch. crystal display (LCD).
CFI: Central Fuel Injection. A computer DV TW: Delay Valve Two-Way.

controlled fuel metering system which
EATC: Electronic Automatic Temperature
sprays atomized fuel into a throttle body
Control.
mounted atop the intake manifold.
"CHECK ENGINE" OR "SERVICE E40D: Electronic 4-Speed Overdrive
ENGINE SOON" LIGHT: A dash panel light transmission.
used either to aid in the identification and ECA: Electronic Control Assembly.
diagnosis of EEC system problems or to
indicate that maintenance is required on ECT: Engine Coolant Temperature sensor
non-EEC equipped vehicles. or its signal circuit.
CID: Cylinder Identification sensor or its EDF: Electro-Drive Fan relay or its control
signal circuit. circuit.
ClC: Converter Lock-up Clutch. EDIS: Electronic Distributorless Ignition
CLUTCH: Clutch engagement switch or its System (high data rate).
control circuit. EEC: Electronic Engine Control. A computer
COC: Conventional Oxidation Catalyst. controlled system of engine control.
COMPUTED TIMING: The total spark EEGR: Electronic EGR Valve (Sonic).
advance in degrees before top dead
center. Calculated by the EEC-IV processor EFI: Electronic Fuel Injection. A computer
based on input from a number of sensors. controlled fuel system that distributes
atomized fuel through an injector located in
CONTINUOUS SELF-TEST: A continuous each intake port of the engine. The fuel
test of the EEC-IV system conducted injectors are fired using bank-to-bank
whenever the vehicle is in operation. circuitry.

ALL RIGHTS RESERVED
Glossary 3
Glossary
EGO: Exhaust Gas Oxygen sensor or its FMEM: Failure Mode Effects Management.
signal circuit. This alternative strategy protects vehicle
function from adverse effects of an EEC
EGOG: EGO Ground. component failure.
EGR: Exhaust Gas Recirculation system FP: Fuel Pump relay or its control circuit.
designed to allow the flow of inert exhaust
gases into the combustion chamber to cool FPM: Fuel Pump Monitor. A circuit in the
the combustion and thus reduce nitrous EEC system used to monitor the electric
oxides in the exhaust. . fuel pump operation on some EEC-IV
equipped vehicles.
EGR S/O: EGR Shut Off.
FTO: Filtered Tach Output. An output from
EGRC: EGR Control vacuum solenoid valve the DIS TFI-IV module which provides a
or its control circuit. filtered ignition signal to the processor in
order to control dwell. .
EGRV: EGR Vent vacuum solenoid valve or
its control circuit. FUEL RICH/LEAN: A qualitative evaluation
of air/fuel ratio based on an A/F value
EHC: Exhaust Heat Control vacuum known as stoichiometry or 14.7. In the
solenoid valve or its control circuit. EEC-IV system rich/lean is determined by a
ENGINE RUNNING SELF-TEST: A test of voltage signal from the EGO sensor. An
the EEC-IV system conducted with the excess of oxygen (lean) is an EGO voltage
engine running and the vehicle at rest. of less than .4 volts, a rich condition is
indicated by an EGO voltage of greater
EPC: Electronic Pressure Control (used in than .6 volts.
E40D transmissions).
FWD: Front Wheel Drive.
ER: Engine Running Self-Test (same as
KOER). GND or GRND: A common ground circuit
for all vehicle power.
ERS: Engine rpm Sensor or its signal
circuit. GOOSE: A brief openning and closing of
the throttle.
EVP: EGA Valve Position sensor or its
signal circuit. HALL EFFECT: A process where current is
passed through a small slice of semi-
EVR: EGR Vacuum Regulator solenoid or conductor material at the same time as a
its control circuit. magnetic field to produce a small voltage
in the semi-conductor.
FBC: Feedback Carburetor. An MCU
controlled fuel system employing a stepper HBV: Heater Blower Voltage input to the
motor or a dithering solenoid that controls EEC-IV processor reflecting heater blower
fuel/air mixture by bleeding air into the' voltage demand.
main and idle systems of the carburetor.
HEDF: High speed Electro-Drive Fan relay
FCS: Fuel Control Solenoid or its control or its control circuit.
circuit.
HEGO: Heated EGO sensor or its signal
FI: Fuel Injector or its control circuit. circuit.
FIPL: Fuel Injection Pump Lever sensor or HEGOG or HEGO GND: Heated EGO
its signal circuit. Ground. .
FLC: Fluid Lock-Up Converter. HIC: Hot Idle Compensator.

ALL RIGHTS RESERVED
4 Glossary
Glossary
HlOS: Hardware Limited Operation KOER: Key On Engine Running Self-Test

Strategy. Certain types of computer (same as Engine Running (ER) Self-Test).
malfunctions will place the EEC-IV
processor into HLOS mode. Output KS: Knock Sensor or its signal circuit.
commands are replaced with fixed values.
l: Liters.
HO: High Output.
lUS: Lock Up Solenoid.
HSC: High Swirl Combustion.
MA or MAF: Mass Air Flow Sensor or its
lAS: Inlet Ai'r Solenoid valve or its control signal circuit.
circuit.
MAP: Manifold Absolute Pressure sensor or
IBP: Integral Back Pressure. its signal circuit.
IDLE liMITER: A device to control
minimum and maximum idle fuel richness. MCU: Microprocessor Control Unit.
The idle limiter is intended to prevent MECS: Mazda Equipped Control System.
unauthorized persons from making overly
rich idle adjustments. MIL: (Malfunction Indicator Light) An
electric circuit between the EEC-IV
10M: Ignition Diagnostics Monitor. A
processor and the "CHECK ENGINE" or
continuous monitor of the ignition input to
"SERVICE ENGINE SOON" light on the
the EEC-IV processor used to detect
dash panel of EEC-equipped vehicles.
intermittent ignition faults.
IGN: Ignition circuit or system. MLP: Manual Lever Position sensor or its
signal circuit.
INJ: Injector (Fuel).
MONITOR BOX: An optional EEC-IV test
INJ GND: Injector Ground (Fuel). device which connects in series with the
EEC-IV processor and its harness, and
IRCM: Integrated Relay Control Module.
permits measurements in various units of
ISC: Idle Speed Control. Currently there are processor inputs and outputs.
two types of computer controlled idle speed
control: DC motor ISC and air bypass ISC. MIT: Manual Transmission
ITR: In-Tank Reservoir. NOS: Neutral Drive Switch or its signal
circuit.
ITS: Idle Tracking Switch. Used on CFI
vehicles to inform EEC if the throttle is in NGS: Neutral Gear Switch or its signal
contact with the DC motor. circuit.
KAM: Keep Alive Memory. A series of NPS: Neutral Pressure Switch or its signal
vehicle battery powered memory locations circuit.
in the microprocessor which allows the
microprocessor to store input failures OASIS: On-line Automobile Service
identified during normal operation for use in Information System.
later diagnostic routines and adapts some
calibration parameters to compensate for OCC: Output Circuit ChQck.
changes in the vehicle system.
OCll: Overdrive Cancel Indicator Light.
KAPWR: Keep Alive Power.
OCS: Overdrive Cancel Switch.
KEY ON ENGINE RUNNING SELF-TEST:
A test of the EEC-IV system conducted OCT ADJ: Octane Adjust device which
with power applied and the engine at rest. modifies spark advance.
KOEO: Key On Engine Off Self-Test. OHC: Overhead Cam.

ALL RIGHTS RESERVED
Glossary 5
Glossary
OPEN CIRCUIT: A circuit which does not RELAY: A switching device operated by a
provide a complete path for the flow of low current circuit which controls the
current. opening and closing of another circuit of
higher current capacity.
OSC: Output State Check.
RELIEF VALVE: A pressure limiting valve
OVERLAY CARD: A plastic card used with located in the exhaust chamber of the
the Monitor box to identify EEC-IV signals thermactor air pump. It functions to relieve
for each engine. The card also programs part of the exhaust airflow if the pressure
the monitor for auto mode measurements. exceeds a calibrated value.
RWD: Rear Wheel Drive.
PCV: Positive Crankcase Ventilation. A
system which controls the flow of SAW: Spark Angle Word. Timing
crankcase vapors into the engine intake information sent from EEC-IV to the EDIS
manifold where they are burned in module. This information is used by the
combustion rather than being discharged EDIS module to calculate final ignition
into the atmosphere. timing.
PFE: Pressure Feedback EGR sensor or its SBS: Supercharger Bypass Solenoid or its
signal circuit. control circuit.
PIP: Profile Ignition Pickup. A "hall effect" SC: Super Charged.

vane switch that furnishes crankshaft SDV: Spark Delay Valve.
position data to the EEC-IV processor.
SEFI: Sequential Electronic Fuel Injection. A
PROCESSOR: EEC-IV Electronic Control computer controlled fuel system that
Assembly. distributes atomized fuel through an injector
located in each intake port of the engine.
PSPS: Power Steering Pressure Switch. An Each injector is fired separately and has
EEC-IV processor input to regulate idle individual circuits.
speed based on power steering load
demand. SELF~TEST: One of three subsets of the
EEC Quick Test: Key On Engine Off,
PULSE AIR SYSTEM: Part of the emission Engine Running, and Continuous.
control system that utilizes a reed-type SHO: Super High Output.
check valve which allows air to be drawn
into the exhaust system as a result of SHORT CIRCUIT: An undesirable
exhaust pulses. connection between a circuit and any other
point.
PVS: Ported Vacuum Switch..
SIG RTN: Signal Return circuit for all
PWR GND: Power Ground. ' sensor signals except HEGO.
QUICK TEST: A functional diagnostic test SIL: Shift Indicator Light. A system that
of the EEC system consisting of vehicle provides a visual indication to the driver of
preparation and hookup, Key On Engine a vehicle when to shift to the next higher
Off, Engine Running and Continuous Self- gear to obtain optimum fuel economy.
Tests. SOLENOID: A wire coil with a moveable
core that changes position by means of
RECORDER: An optional EEC-IV test electro-magnetism when current flows
device which works jointly with the Monitor through the coil.
box. It allows up to 8 EEC-IV signals to be
electronically recorded over a 50 second SPOUT: Spark Output Signal from the
period. EEC-IV processor.

ALL RIGHTS RESERVED
6 Glossary
Glossary
SS1: Shift Solenoid 1 or its control circuit. TIMING: Relationship between spark plug
firing and piston position usually expressed
SS2: Shift Solenoid 2 or its control circuit. in crank shaft degrees before (BTDC) or
after (ATDC) top dead center of the
SS 3/4-4/3: (Shift Solenoid 3/4-4/3) Output compression stroke.
from the EEC-IV processor to the
transmission that selects 3rd and 4th gears. TIV: Thermactor Idle Vacuum Valve.
TK: Throttle Kicker vacuum solenoid valve
STAR: Self-Test Automatic Readout. A or its control circuit.
testing device in which the EEC and MCU
systems output service codes in a digital TOT: Transmission Oil Temperature Sensor
format. or its signal circuit.
STI: Self Test Input circuit in the EEC and TP: Throttle Position sensor or its signal
MCU systems used to initiate Self-Test. circuit.
TSP: Throttle Solenoid Positioner.
STO: Self Test Output circuit in the EEC
and MCU systems that transmits service TTS: Transmission Temperature Switch.
codes (pulses) to either a VOM or STAR
tester. TVS: Temperature Vacuum Switch.
TVV: Thermal Vent Valve.
TAB/TAD: Thermactor Air Bypass/
Thermactor Air Diverter vacuum solenoid TWC: Three Way Catalyst.
valves or their control circuits.
VAF: Vane Air Flow sensor or its signal
TCP: Temperature Compensated circuit.
(Acceleration) Pump.
VAT: Vane Air Temperature sensor or its
signal circuit.
TFI: Thick Film Ignition. An ignition module
comprised of a custom integrated circuit, VBAT: Vehicle Battery voltage.
Darlington output device and associated
thick film integrated components. VCK-V: Vacuum Check Valve.
TGS: Top Gear Switch. A lock out VCV: Vacuum CO':ltrol Valve.
mechanism that prevents the Sl L from VDV: Vacuum Delay Valve.
lighting when the vehicle is in top gear.
VM: Vane Meter.
THERMACTOR: A system for injection of
air into the exhaust system to aid in the YOM: Volt-Ohm Meter used to measure
voltage and resistance. Readings are
control of hydrocarbon and carbon
indicated by sweep hand on a printed
monoxides in the exhaust.
scale rather than a digital display.
THERMACTOR II: See Pulse Air System. VOTM: Vacuum Operated Throttle
Modulator.
THS: Transmission Hydraulic Switch. An
input to the processor that indicates the VPWR: Vehicle Power supply voltage
occurance of a shift between specific regulated to 10-14 volts.
gears.
VR/S: Vacuum Regulator/Solenoid.
THS 3/2: Transmission Hydraulic VRDV: Vacuum Retard Delay Valve.
Switch 3rd/2nd gear.
VREF: Reference voltage supplied by the
THS 4/3: Transmission Hydraulic EEC-IV processor to some sensors and
Switch 4th/3rd gear. regulated to 4-6 volts.

ALL RIGHTS RESERVED
Glossary 7
Glossary
VRESER: Vacuum Reservoir. VSS: Vehicle Speed Sensor or its signal

circuit.
VREST: Vacuum Restrictor.
VVA: Venturi Vacuum Amplifier.
VR or VRS: Variable Reluctance Sensor. A
non-contact transducer that converts VVC: Variable Voltage Choke relay or its
mechanical motion into electrical control control circuit.
signals.
VVV: Vacuum Vent Valve.
VRV: Vacuum Regulator Valve.
WAC: Wide-open throttle AIC Cutoff.
VSC: Vehicle Speed Control sensor or its
signal circuit. WOT: Wide-Open Throttle.

ALL RIGHTS RESERVED
SECTION 1
Emission Control
Identification/Application
Contents
Vehicle Emission Control Information Decal 1-1
Vehicle Emission Control Information Decal Location 1-2
Emission Control Application:
Car 1-3
Light Truck 1-4
Medium/Heavy Truck 1-5

ALL RIGHTS RESERVED
Emission Control IdentlflcatlonlApplication 1-1
Vehicle Emission Control Information Decal
Each vehicle is equipped with a decal (Figure. 1) containing emission control data that applies
specifically to that vehicle and engine. The specifications provided on the decal are critical to
servicing emissions systems.
FORD MOTOR COMPANY 1IIlCUUM HOlE MlUTINQ

IMPORTANT VEHICLE INFORMATION
'nlll y[HICU IS EOUII-1tC WITH HC IVIE..I I"ST'DIS. IIll.! "aos
AND IIll.! _xTURES ME NOT ADoIUITAilLE. I[ SHOP IIAIlUAL FOR
ADDITIONAL I....ORIllATIO...
ADoIUIT IQIIITIOII TIMING WITH THE TRANSMISIION IN NEUtRAL, PARKING
aRAKE SET MIl THE WHEELS aLOtKtD. ENGINE lIIlST aE AT "OAIIAL
OnRATlllG TDlPEIlATU!t.
III TURII 0" ENGI NE.
(II OIICO. .CT THE 1lH.11lE SPOUT COIlIlECTOR (~. I.
lS' lit-START PREVIOUSLY WARIIRO-UP NGtIl.
(", ADoIUIT IUITION TIMING TO 10 aTOe.
(51 TURN 0" ENGINE ANO "STOllE ELECTRICAL COIMCTIOIl.
THIS YEHICU CO.... O". . TO U.S. EPA /lIIIO CALIFORNIA IttGULATIOItS

AP~ICAIlU TO 1981 lIOOlL YEAR NEW LIOHT-oun TRUCKS INTRODUCED
'NTO COMlllRCE IOLLY FOR SALE IN CALI..ottNIA.
- - .. ... A12711-A
Figure 1 Typical Vehicle Emission Control Information Decal
In addition to the tune-up specifications and procedures_ the emission decal shows a color
coded schematic of the engine vacuum system. The color coding on the schematic represents
the actual color coding on the vacuum hoses. However, there will be instances where an
individual hose color will not agree.

ALL RIGHTS RESERVED
1-2 Emission Control Identification/Application
Vehicle Emission Control Information Decal Location
VEHICLE EMISSION CONTROL INFORMATION DECAL LOCATION

VEHICLE LOCATION
Escort 1.9L Radiator Sight Shield
Tempo/Topaz 2.3L Resonator Assembly
Mustang 2.3L, 5.0L Coil Appearance Cover
Thunderbird/Cougar 3.8L Radiator Support
Taurus/Sable 2.5L, 3.0L, 3.8L Radiator Sight Shield
Continental 3.8L Radiator Sight Shield
Crown Victoria/
Fan Shroud
Grand Marquis 5.0L, 5.8L
Mark VII, Lincoln Town Car 5.0L Fan Shroud
Ranger, Bronco II, Aerostar All Engines Radiator Support
Econoline All Engines Under Hood
F-Series All Engines Under Hood
Engine Calibration Identification
The Emission Calibration Number Label, which contains the engine calibration number, is
located on the driver's side door or door post pillar.
, ,
CALIBRATION
ETALONNAGE ~
CALI BRACION
\. j;76A-ROO E9"'E~061ABY
ENGINE CALIBRATION
NUMBER
A9427B
Figure 2 Emission Calibration Number Label

ALL RIGHTS RESERVED
Emission Control IdentlflcationlApplication 1-3
Emission Control Application
PASSENGER CAR - 50 STATES/CANADA
Catalyst(s) Idle
Vehicle Fuel System Electronic EGR secondary Ignition Speed
"Engine Application Type Location Type, Mfg Eng Ctrl System Air System System Control
Close
1.9L Escort TWC CFI EEC-IV PFE None TFI-IV DCM
Mount
Close
1.9L Escort/Tracer TWC EFI EEC-IV PFE None EDIS BPA
Mount
TWC
1.9L HO Escort DBUB EFI EECIV BVT Dual PA TFI-IV BPA
COC
TWC TB EFI
2.3l0HC Mustang EEC-IV EEGR None TFI-IV BPA
TWC UB Calif-MA
2.3L HSC
TWC &
49 States/ PA
Tempo/Topaz COC DBUB EFI EEC-IV PFE TFI-IV BPA
Canada
California TWC : MTA
2.3l HSC
Plus 49 TWC &
PA
States/ Tempo/Topaz COC DBUB EFI EEC-IV PFE TFI-IV BPA
Canada
California TWC MTA
TWC
2.5L HSC Taurus DBUB CFI EECIV EEGR PA TFIIV DCM
COC
2.9L Scorpio TWC DBUB EFI EEC-IV None None TFI-IV BPA
Probe TWC UB EFI EEC-IV TFIIV
None
3.0L None Calif-TFI- BPA
Taurus TWC UE EFI EECIV Calif-PFE
IV/CCD
None
3.0L SHO Taurus/Sable TWC UE SEFI-MA' EEC-IV None DIS BPA
Calif-PFE
Thunderbird/ (2) TWC
3.8L SC TB SEFI-MA EEC-IV PFE None DIS BPA
Cougar TWC
Thunderbird/ (2) TWC TFI-IV/
TB SEFI EEC-IV PFE None BPA
Cougar TWC CBD
(2) TWC TB TFf-IV/
3.8L Continental SEFI EEC-IV PFE CT BPA
TWC UB CBO
(2) TWC' TB TFI-IV/
Taurus/Sable SEFI EEC-IV PFE CT BPA
TWC UB CBD
Crown Victoria/
SEFI
Grand Marquis (2) TWC TB SPA .
5.0L Calif EEC-IV EEGR MTA TFI-IV
Ford Police (2) cae US
SedansMA
Town Car
(2) TWC TB
Mustang SEFI-MA EEC-IV EEGR MTA TFI-IV BPA
(2) COC UB
5.0l HO
(2) TWC TB
Mark VII SEFI EEC-IV EEGR MTA TFI-IV BPA
(2) COC UB
Crown Victoria/
Grand Marquis (2) TWC 7200-VV
5.8L DBUB MCU IBP MTA OS 1/ TSP
(Canada) cae FBC. Ford
Ford Police
ABBREVIATIONS:
BPA - Bypass Air EOIS = Electronic Oistributorless Ignition MFG = Manufacturer

BVT - Back Pressure Variable Transducer " System (high data rate) MTA = Managed Thermactor Air
CCD - Computer Controlled Dwell EEC-IV = Electronic Engine OHC = Overhead Cam
CFI - Central Fuel Injection Control - System-IV PA = Pulse Air
cae - Conventional Oxidation EEGR = Electronic EGR Valve PFE = Pressure Feedback Electronic
Catalyst (Sonic) SEFI = Sequential EFI
CT - Conventional Thermactor EFI = Electronic Fuel Injection TB = Toe Board
DBUB .. Dual Brick Underbody EGR = Exhaust Gas Recirculation TFI = Thick Film Ignition
DCM - D.C. Motor HSC = High Swirl Combustion TSP =
Throttle Solenoid Positioner
DIS - Oistributorless Ignition System IBP = Integral Back Pressure TWC = Three-Way Catalyst
(low data rate) MA = Mass Air UB =
Underbody
OS-II - Duraspark II MCU = Microprocessor Control Unit

ALL RIGHTS RESERVED
1-4 Emission Control IdentificationlApplication
LIGHT TRUCK - 50 STATES/CANADA
Catalyst(s) Fuel Idle

Vehicle System Electronic EGR Secondary Ignition Speed
Engine Application Type Location Type, Mfg Eng Ctrl System Air System System Control
2.3L TWC
Ranger DBUB EFI EEC-IV EEGR None DIS BPA
OHC TWC
Ranger/ TWC
2.9L (2) SBUB EFI EEC-IV None None TFI-IV BPA
Bronco II TWC
2.9L Ranger/ TWC US #1
EFI-MA EEC-IV None None EDIS BPA
MA Bronco II TWC UB #2
TWC
3.0L Aerostar (2) SBUB EFI EEC-IV None None TFI-IV BPA
TWC
Ranger,
4.0L TWC UB #1
Bronco II EFI-MA EEC-IV None None EDIS BPA
MA TWC UB #2
Aeroster
E-Series/
TWC UB #1 * MTA/
4.9L F-Series EFI EEC-IV EEGR TFI-IV BPA
(2) CDC UB #2 AM1, AM2
Bronco
E-Series/
TWC UB #1 MTA/
Bronco
E-Series/
TWC UB #1 MTA/
Bronco
ABBREVIATIONS:
AM1, AM2 = Air Management 1, 2 EFI = Electronic Fuel Injection

BPA = Bypass Air MA = Mass Air
CDC = Conventional Oxidation Catalyst MTA = Managed Thermactor Air
CT = Conventional Thermactor NFB = Non-Feedback Carburetor
DBUB = Dual Brick Underbody PFE = Pressure Feedback Electronic
DCM = D.C. Motor SBUB = Single Brick Underbody
DIS = Distributorless Ignition System TFI-IV = Thick Film Ignition
(low data rate) TWC = Three-Way Catalyst
OS-II = Duraspark II . UB = Underbody
EEC-IV = Electronic Engine Control - System-IV
EEGR = Electronic EGR Valve (Sonic)
EDIS = Electronic Distributorless Ignition
System (high data rate)
* All 4.9L light trucks weighing under 8500 Ibs. with an automatic transmission calibration use MTA/AM7 only.

ALL RIGHTS RESERVED
Emission Control IdentlflcationlApplication 1-5
MEDIUM/HEAVY TRUCK - 50 STATES/CANADA
Catalyst(s) Idle
Vehicle Fuel System Electronic EGR Thermactor Ignition Speed
Engine Application Type Location Type, Mfg Eng Ctrl System System System Control
E-Series/ TWC UB #1 MTA/
4.9L EFI EEC-IV EEGR TFI-IV BPA
F-Series COC UB #2. AM1, AM2
E-Series/ MTA/
5.8L REDOX UB EFI EEC-IV EEGR TFI-IV BPA
F-Series AM1, AM2
2380EG-2V
6.1L F-Series None NA None Ported CT OS-II None
Holley
4190EG-4V
7.0L F-Series None NA None Ported CT OS-II None
Holley
E-Series/ (3) TFI-IV/
7.5L UB EFI EEC-IV EEGR MTA BPA
F-Series REDOX CBO
ABBREVIATIONS:
AM1, AM2 = Air Management 1, 2 MFG = Manufacturer

BPA = Bypass Air MTA = Managed Thermactor 'Air
CBD = Closed Bowl Distributor NA = Not Applicable
COC = Conventional Oxidation Catalyst REDOX = Reduction-Oxidation
CT = Conventional Thermactor TFI-IV = Thick Film Ignition
OS-II = Duraspark !I TWC = Three-Way Catalyst
EEC-IV = Electronic Engine Control - System-IV UB = Underbody
EEGR = Electronic EGR Valve (Sonic) V = Venturi
EFI = Electronic Fuel Injection
EGR = Exhaust Gas Recirculation

ALL RIGHTS RESERVED
SECfION 2
Diagnostic Routines
Contents
Preface to Diagnostic Routines 2-1
Diagnostic Routine Index 2-2
Diagnostic Routines 2-3

ALL RIGHTS RESERVED
Diagnostic Routines
PREFACE
The Diagnostic Routines list the components and systems that can contribute to a particular
condition in the order of probability, ease of accomplishment, and accessibility. These Routines
can be used as check lists for reference in the event of unusual or infrequent causes of
malfunction.
It is not necessary that any given order be followed, but it makes good sense for the
technician to visually inspect everything that his experience tells him could be the source of
the condition before beginning a m~re involved diagnosis. The effectiv~ness of every service
must be validated.
All references, under the REFER~NCE column in each Diagnostic Routine chart, are a~
follows:
'Group titles reference specific groups shown in the Powertrain, or Body, Chassis and
Electrical Shop Manuals..
Section numbers reference sections in the Engine/Emissions Diagnosis manual.
Special manual publications are referenced in some cases.
On-line Automotive Service Information System (OASIS) numbers have been included where
applicable. '

ALL RIGHTS RESERVED
22 Diagnostic Routines
Diagnostic Routine Index
. GASOLINE ENGINES
OASIS
Title Routine Page
Number
Cranks Normally But Won't Start 201 610200 2-3
Starts Normally But Won't Run (Stalls) 202 620100 2-4
Cranks Norl"flally But Slow to Start 203 610300 2-5
Rough Idle 204 620800 2-6
Misses Under load 205 630300 27
low Idle (Stalls on Deceleration or Quick Stop) 206 630103 2-7
Hesitates or Stalls on Acceleration 207 631900 2-8
Backfire (Induction or Exhaust) 208 630600 2-9
lack of Power 209 630400 2-10
Surges at Steady Speed 210 630200 2-11
High Idle (Engine Diesels) 211 620700, 640100 212
Engine Noise 212 4400 2-13
Poor Fuel Economy 213 640200 2-14
High Oil Consumption 214 4101 2-15
Spark Knock/Pinging 215 632500 2-15
Engine Vibrates at Normal/High Speeds 216 7210 2-16
Engine Runs Cold 217 4300 2-16
Engine Runs Hot 218 4300 216
Exhaust Smoke 219 - 2-17
Gas Smell 220 - 218
"CHECK ENGINE" /"SERVICE ENGINE SOON" Light Always
On or Never On "CHECK ENGINE" /"CHECK DCl" Message On
221 - 2-18
State Emission Test Failure 222 - 2-19

Improper Shift 223 5101, 5102 2-21
Shift Indicator Light and Audible Chimes "ON" 224 - 2-21
DIESEL ENGINES
Title Routine Page
6.6l and 7.8l Engines 20-1
7.3l Engine (Engine Induced Faults) 21-1
7.3l Engine (Transmission Induced Faults)
low Idle (Stalls on Deceleration or Quick Stop) 206 2-7
Hesitates or Stalls on Acceleration 207 2-8
lack of Power 209 210
High Idle (Engine Diesels) 211 2-12
Poor Fuel Economy 213 2-14
Improper Shift 223 221

ALL RIGHTS RESERVED
Diagnostic Routines
201 CRANKS NORMALLY BUT WON'T START

(OASIS #610200)
NOTE: Extended cranking, because of a "No Start" condition, can load the exhaust system
with raw fuel, which can ruin the catalytic converter after the engine starts. After the
"No Start" condition has been repaired, disconnect the thermactor air supply, run
the engine until surplus fuel Is used up and reconnect the thermactor air supply.
System Component Reference

EEC Quick Test Section 14
Ignition Electrical Connections
Secondary Ignition Wires
Spark Plugs Fouled
Ignition Switch
OS" and TFI IV: DSII and TFI IV:
Ignition Coil Section 13, Ignition/Engine
Ignition Module Group
Rotor Alignment
Distributor Cap, Adapter, Rotor & Stator
DIS/EDIS: DIS/EDIS:
Single or Dual Hall Crankshaft Sensors Section 14, Section 13,
Hall Camshaft Sensor Ignition/Engine Group
DIS/EDIS Ignition Module
Coil Pack(s)
Fuel Delivery Filter Visual, Section 11,
Pump Fuel/Engine Group
Water/Dirt/Rust Contamination in Fuel
Lines
Tank (Fuel Supply)
Dual Tanks (Selector Switch)
Sender Filter
Fuel Pressure Regulators for EFI and CFI
Injectors
Inertia Switch
Fuel Charging Electrical Connections Visual, Section 4,
Assy.lThrottle Choke Plate and Linkage Fuel/Engine Group
Body/ External Carburetor Cold Enrichment Rod and Linkage (7200)
Venturi Valve (7200)
Throttle Linkages
Internal Carburetor Float/lnlet Needle and Seat Section 4, Fuel/Engine Group
Idle Air Bleeds and Fuel Passages
Basic Engine Camshaft Timing Engine Group
Compression
EGA Valve Section 6
MCU Component Diagnostics Special MCU Diagnosis
Manual
Exhaust Catalyst Exhaust Visually inspect for blockage.

ALL RIGHTS RESERVED
2-4 Diagnostic Routines
Diagnostic Routines
202 STARTS NORMALLY BUT WON'T RUN

(STALLS)
(OASIS #620100)
Fuel Charging Curb or Fast Idle Speed Visual, Section 4,
Assy/Throttle Electrical and Vacuum Connections Fuel/Engine Group
Body/ External Carburetor Choke Plate and Linkage
Cold Enrichment Rod And Linkage (7200)
Choke Pulldown Adjustment & Diaphragm
Choke Cap Indexing
Lines
Tank (Fuel Supply)
Sender Filter
Injectors
Inertia Switch
Ignition Electrical Connections
Secondary Ignition Wires
Ignition Switch
DSII and TFI IV: DSII and TFI IV:
Ignition Coil Section 13, Ignition/Engine
Ignition Module Group
Rotor Alignment
Distributor Cap, Adapter, Rotor & Stator
Ballast Resistor
DIS/EDIS: DIS/EDIS:
Single or Dual Hall Crankshaft Sensors Section 14, Ignition/Engine
Hall Camshaft Sensor Group
Coil Pack(s)
Internal Carburetor Float/Inlet Needle and Seat Fuel/Engine Group
Idle Air Bleeds and Fuel Passages
Exhaust Component (Restricted) Section 5
EGR Valve Section 6
Manual
Basic Engine Camshaft and Valve Train Engine Group
Induction Intercooler Tube (Air Leaks) Section 8
(Supercharger)

ALL RIGHTS RESERVED
Diagnostic Routines
203 CRANKS NORMALLY BUT SLOW TO START

(OASIS # 61 0300)
NOTE: It is a good practice to confirm that the correct starting procedure was being used
by the customer before proceeding with diagnosis.

Ignition Scope Engine for: Spark Plugs, Coil, Secondary
Ignition Wires
Spark Plugs Fouled
0511 and TFI IV: DSII and TFI IV:
Distributor Cap, Adapter & Rotor Visual, Section 13,
Ignition/Engine Group
DIS/EDIS: DIS/EDIS:
Single or Dual Hall Crankshaft Sensors Section 14, Ignition/Engine
Hall Camshaft Senso Group
Coil Pack(s)
Fuel Delivery Filter Visual, Section 11, Fuel/Engine
Pump Group
Lines
Sender Filter
Injectors
Fuel Charging Assy/Throttle Curb or Fast Idle Speeds Visual, Section 4, Fuel/Engine
Body/ External Carburetor Electrical and Vacuum Connections Group
Choke Plate and Linkage
Cold Enrichment Rod and Linkage (7200)
Choke Cap Indexing
Accelerator Pump
Bowl Vents
Internal Carburetor Float/Inlet Needle and Seat Visual, Section 4, Fuel/Engine
Stepper Motor (7200) Group
Cold Enrichment System (7200)
Exhaust Component (Restricted) Section 5
Induction and Vacuum Vacuum Leaks Visual, Audible, Engine Group
Distribution Air Cleaner Element Restricted
Cooling Electric Fan (Hot Start Only) Cooling/Engine Group
EGR Valve Section 6
PCV Valve Section 9
EVAP Components Section 7, Fuel/Engine Group
MCU Component Diagnostics Special MCU Diagnosis Manual

ALL RIGHTS RESERVED
Diagnostic Routines
204 ROUGH IDLE

(OASIS # 620800)
Cooling Fan or Electric Fan (Loose or Cracked) Visual
Ignition Scope Engine For: Spark Plug, Coil, Section 13, Ignition/Engine
Secondary Wires, Distributor Cap, Adapter Group
and Rotor
Ignition Timing
Fuel Charging Curb or Fast Idle Speeds Visual, Section 4,
Assy/Throttle Electrical and Vacuum Connections Fuel/Engine Group
Body/External Carburetor Choke Plate and Linkage
Choke Pulldown
Bowl Vent
Fuel Delivery Fuel Pressure Regulators EFI/CFI Section 11, Fuel/Engine
Injectors Group
Fuel Rail
Carburetor Idle Mixture Section 4
Internal Carburetor Idle, Air Bleeds or Fuel Passages Visual, Section 3, Section 4,
Float/Inlet Needle and Seat Fuel/Engine Group
Stepper Motor (7200)
Hot Idle Compensator (may be external)
Altitude Compensator "
Vacuum Distribution Vacuum Leaks Visual and Audible
EGR Valve Section 6
Vacuum Regulator
Cooling Thermostat Cooling/Engine Group
Basic Engine Compression Engine Group
Valve Train
Camshaft
Intake Manifold Gaskets
PCV Valve Section 9
Exhaust Pipes, Muffler, Catalyst Section 5
Resonator, Heat Control Valve
Induction Intercooler Tube (Air Leaks) Section 8
(Supercharger)
Manual

ALL RIGHTS RESERVED
Diagnostic Routines
205 MISSES UNDER LOAD

(OASIS # 630300)
Ignition Scope Engine For: Spark Plug, Coil, Secondary Section 13, Ignition/Engine
Wires, Distributor Cap, Adapter and Rotor Group
Timing
, EEC Quick Test Section 14
Fuel Delivery Filter Visual, Section 4, Section 11,
Lines .
Fuel Pressure Regulators EFI/CFI
Sender Filter
Injectors
Fuel Charging Electrical and Vacuum Connections Visual, Section 4, Fuel/E~gine
Assy/Throttle Choke and Linkage Group
Body/External Carburetor Cold Enrichment Rod and Linkage (7200)
Venturi Valves (7200)
Internal Carburetor Basic: Idle, Main, and Accelerator Pump Visual, Section 3, Fuel/Engine
Float/Inlet Needle and Seat Group
Main Metering
Fuel Enrichment
EGR Valve Section 6
206 LOW IDLE

(STALLS ON DECEL OR QU'ICK STOP)
(OASIS #630103)
Fuel Charging Curb or Fast Idle Speed Visual, Section 4, Fuel/Engine
Assy/Throttle Electrical and Vacuum Connections Group
Body/ ExternalCarburetor Throttle Devices
Internal Carburetor Idle Airbleeds or Fuel Passages Visual, Section 4, Fuel/Engine
Stepper Motor (7200) Group .
Hot Idle Compensator (may be external)
Float/Inlet Needle and Seat
EGR Valve Section 6
Base Transmission (E40D Transmission Oil Level Transmission Group
Only) Converter Clutch Control Solenoid

ALL RIGHTS RESERVED
Diagnostic Routines
207 HESITATES OR STALLS ON ACCELERATION

(OASIS #631900)
Ignition Scope Engine For: Spark Plug, Coil, Section 13, Ignition/Engine
Secondary Wires, Distributor Cap, Adapter Group
and Rotor
Ignition Timing
Fuel Charging Choke Plat and Linkage Visual, and Section 4
Assy/Throttle Electrical & Vacuum Connections
Body/ External Carburetor Cold Enrichment Rod and Linkage (7200)
Accelerator Pump
Curb or Fast Idle Speeds
Lines
Sender Filter
Injectors
Internal Carburetor VV Diaphragm (7200) Section 4, Fuel/Engine Group
Power Valve
Main System
Induction Air Cleaner Duct, Stove Pipe, and Valve Section 8
Inter-Cooler Tube (Air Leaks)
EGR Valve Section 6
PCV Valve Section 9
Manual
Exhaust (Restriction) With Backpressure EGR System Section 5
Base Transmission Converter Clutch Control Solenoid Transmission Group
(E40D and A4LD) Converter Clutch Override
Converter Clutch

ALL RIGHTS RESERVED
Diagnostic Routines
I
208 BACKFIRE (INDUCTION OR EXHAUST)
(OASIS IF 630600)
Ignition Scope Engine For: Spark Plug, Coil, Section 13
Secondary Wires, Distributor Cap and Rotor,
Crossed Wires
Ignition Timing
Vacuum Distribution Vacuum Hoses, or Connections Leak(s) Visual and Audible
Thermactor Thermactor System Components Section 10
Pulse Air Pulse Air System Components Section 10
Basic Engine Intake Manifold Gaskets Engine Group
Compression Check
Camshaft
Valves
Exhaust Components (Restricted) Section 5
Water, Dirt, Rust, Contamination in Fuel
Lines
Fuel Pressure Regulators EFI/CFI
Injectors
Sender Filter
External Carburetor Choke Plate and Linkage Visual and Section 4
Manual

ALL RIGHTS RESERVED
Diagnostic Routines
209 LACK OF POWER

(OASIS # 630400)
Ignition Timing Section 13
Lines
Fuel Pressure Regulator EFI/CFI
Sender Filter
Injectors
Fuel Charging Electrical and Vacuum Connections Visual, Section 4,
Assy/Throttle Choke Plate and Linkage Fuel/Engine Group
Body/ External Carburetor Accelerator Pump
Curb or Fast Idle Speed
Internal Carburetor Float Inlet/Needle and Seat Visual, Section 4,
Accelerator Pump Fuel/Engine Group
Main Metering System
Fuel Enrichment
Altitude Compensator
Pullover Rod Sticking (1949)
Ignition Scope Engine For: Spark Plugs, Coil, etc. Visual, Section 13,
Ignition/Engine Group
Exhaust Components (Restricted) Section 5
Vacuum Distribution Vacuum Leaks Visual/Audible
Induction Air Cleaner Duct and Valve and Element Section 8
EGR Valve Section 6
Basic Engine Compression Check Fuel/Engine Group
Camshaft
Valves
Drive Train Clutch, Automatic Transmission, Brakes Transmission Group, Driveline
Group
Manual
Supercharger Assembly Fuel/Engine Group

ALL RIGHTS RESERVED
Diagnostic Routines
210 SURGE AT STEADY SPEED

(OASIS # 630200)
Lines
Sender Filter
Fuel Charging Choke Plate and Linkage Visual, Section 4,
Assy/Throttle Electrical & Vacuum Connections Fuel/Engine Group
Body/ External Carburetor Venturi Valves (7200)
Curb or Fast Idle Speeds
Internal Carburetor Idle, Main Systems Visual, Section 4,
Float/Inlet Needle and Seat Fuel/Engine Group
Fuel Enrichment Systems
Altitude Compensator .
Ignition Scope Engin~ For: Spark Plugs, Coil, Section 13
Secondary Ignition Wires, etc., Timing
Vacuum Distribution Vacuum Leaks Visual, Audible
EGR Valve Section 6
Induction Air Cleaner Duct and Element Visual, Section 8
Basic Engine Valve Train and Camshaft Engine Group
Manual
Supercharger Assembly Fuel/Engine Group

ALL RIGHTS RESERVED
Diagnostic Routines
211 HIGH IDLE (ENGINE DIESELS)

(OASIS #620700, 640100)
NOTE: If engine idles smoothly after key is turned off, trouble is likely to be in the ignition
switch, ignition harness, starter solenoid "IGN" tap, or EEC relay.

Fuel Charging Curb or Fast Idle Speeds Visual, Section 4,
AssyIThrottle Electrical and Vacuum Connections Fuel/Engine Group
BodyI External Carburetor Throttle Positioner or Dashpot
Throttle Plate and Linkage
Fast Idle Linkage
Speed Control Chain
Induction Vacuum Leaks Engine Group
Cooling Overheating Routine 218

ALL RIGHTS RESERVED
Diagnostic Routines
212 ENGINE NOISE

(OASIS # 4400)
Squeal, Click, or Chirp .Oil Level (low) Visual, Audible, Engine
Valve Train Group, Cooling Group
Drive' Belts (loose),
Belt Driven Components
EEC Solenoids
Rumble, Grind Belt Driven Components

Rattle Component (loose) Exhaust Group
Hiss Thermactor System (leak) Visual, Audible, Section 10,
Vacuum Distribution System (leak) Engine Group
Induction System (leak):
Spark Plug (loose)
Cooling System (leak) Visual and Audible
EVAP System (leak) Section 7
Snap Secondary Ignition Visual and Audible
Rap, Roar Exhaust System (leak) Visual, Audible, Section 1O,
Pulse Air System (air cleaner) Exhaust Group
Knock Connecting Rod Bearing (worn) Engine Group
Main Bearing (worn)
Piston Pin (loose)
Piston to Bore Clearance (cold engine)
Mechanical Fuel Pump Fuel/Engine Group
Detonation Routine 215

ALL RIGHTS RESERVED
Diagnostic Routines
213 POOR FUEL ECONOMY

(OASIS # 640200)
NOTE: Since fuel consumption is drastically increased for city driving, short-run operation,
stop and go driving, trailer towing, extended winter warm-up periods, etc., as
opposed to "trip" mileage, an attempt should be made to determine these factors
when confronted with "poor mileage" conditions. However, since the operator Is not
always at fault, the following is appended:

Fuel Charging Choke Plate and Linkage Visual, Section 4
Assy/Throttle Cold Enrichment Rod and Linkage (7200)
Body/ External Carburetor Electrical & Vacuum Connections
Fuel Delivery Fuel Return Line Blocked Section 11, Fuel/Engine
Fuel Pressure Regulators EFI/CFI Group
Induction Air Cleaner Duct and Valve Visual, Section 8
Air Cleaner Element (Restricted)
Ignition Scope Engine For: Spark Plug, Coil, Section 13
Secondary Wires, Distributor Cap, Adapter
and Rotor
Ignition Timing
Internal Carburetor Idle, Main Systems Section 4, Fuel/Engine Group
Enrichment Systems
Float/Inlet Needle and Seat
Manual
Factors External to the Tire Pressure & Type Manual and Visual
I Engine Clutch Operation
Converter Clutch Override
Automatic Transmission Shift Pattern and
Fluid Level
Brake Drag
Exhaust System
Speedometer/Odometer Gear Ratio
Axle Ratio
Vehicle Load
Road & Weather Conditions
Aftermarket Add-Ons
Base Transmission Converter Clutch Control Solenoid Transmission Group
(E40D Only)

ALL RIGHTS RESERVED
Diagnostic Routines
214 HIGH OIL CONSUMPTION

(OASIS #4101)
NOTE: If the condition cannot be verified, clean engine, if necessary, change oil and filter
(at customer's expense), seal and have customer drive 500 miles (804.5 Kmlor
enough distance to consume two quarts before returning for re-examination.
System CompQnent Reference

External Leaks Rocker Cover Gasket, Crankshaft Seals, Engine Visual
Assembly
Proper Dipstick Overfilling (sometimes accomplished by the Manual and Visual
"short stick" gas station procedure).
Induction Air Cleaner Element (Sealing) Visual, Fuel/Engine Group
pcv Valve Section 9
Internal Leaks (blue smoke Valve Guides Engine Group
from tailpipe) Valve Stem Seals
Intake Manifold and Gasket
Cylinder Head Drain Passages
Piston Rings
215 SPARK KNOCK/PINGING

(OASIS # 632500)
NOTE: If the above fails to correct the condition, it is recommended that the owner change
his source of fuel and use higher octane fuel. .

Vacuum Distribution Vacuum Leaks Visual, Audible, and Section 3
Spark Delay Valve
PVS
Cooling Overheating Visual, Routine 218
Basic Engine Oil Level Engine Group
Compression Check
Intake Manifold Gasket
Fuel Delivery Injectors Section 11
PCV Valve Section 9
EGR Verity correct application, then diagnose. Section 6
Induction Air Cleaner Duct and Valve Assembly Section 8
Base Transmission (E40D Transmission Controls Transmission Group
Non-Diesel Only)

ALL RIGHTS RESERVED
Diagnostic Routines
216 ENGINE VIBRATES AT NORMAL SPEEDS

(OASIS #7210)
Engine Accessories Fan Manual and Visual
Belt Driven Components
Engine Mounts
Engine Vibration Damper
Otherwise Non-Engine Components: Drive Line, Tires, Manual and Visual
Wheel Balance
3.8L Supercharged Shift Indicator Light and Audible Chime Routine 224
"ON"
217 ENGINE RUNS COLD

(OASIS # 4300)
Gauge System Gauge, Sender Instruments/Gauge
218 ENGINE RUNS HOT

(OASIS # 4300)
Cooling Thermostat Visual, Cooling/Engine Group
Coolant Level
Radiator or A/C Condenser
Pressure Cap and Overflow System
External Leaks
Belts and Belt Tension
Fan and Fan Clutch
Electric Fan (If So Equipped)
Gauge System Gauge, Sender Instruments/Gauge Group
Vacuum Distribution Spark Delay Valve Section 3
Basic Engine Oil Level Engine Group
Internal Leak(s)
Core Sand in Head/Block
Water Pump
Manual
Brake Brakes (dragging) Brake Group

ALL RIGHTS RESERVED
Diagnostic Routines
219 EXHAUST SMOKE

NOTE: White Smoke is normal during warm-up.

Black Smoke (rich Choke Plate and Linkage Section 4, Fuel Group
mixture) Cold Enrichment Rod and Linkage (7200)
Air Cleaner Element (Restricted) Visual
Internal Carburetor Components: Visual, Section 4,
Basic: Idle, Main and Accelerator -Pump Fuel/Engine Group
Metering Systems
Enrichment Systems
Fuel Inlet Needle/Seat
Float
Fuel Pressure Regulator EFI/CFI Section 11, Fuel/Engine
Injectors Group
EEC Components Section 14
MCU Components Special MCU Diagnosis
Manual
Blue Smoke (burning oil) PCV Valve Section 9
Valve Guides/Stems/Seals Engine Group
.Oil Drain Passages in Head
Rings (not seated, seized, gummed up, worn) Engine Group
Cylinder bores (scuffed)
White Smoke (coolant in Thermactor Vacuum Delay Valve (restricted) Section 6, Engine. Group
combustion) EGR Cooler
Intake Manifold (cracked/porous)
Cylinder Head/Gasket (leaks)
~
Block (cracked/porous)

ALL RIGHTS RESERVED
Diagnostic Routines
220 GAS SMEll

Fuel Delivery Fuel Filter (leaks) Visual, Section 11,
Fuel Line to Carburetor (leaks) Fuel/Engine Group
Injectors (leaking)
Fuel Pump (leaks)
Fuel Line, Pump to Tank (leaks)
Fuel Tank (leaks)
Fuel Tank Filler Neck/Cap (leaks)
Fuel Return Line (Blocked)
Internal Carburetor Float/Inlet Needle (stuck) Section 4, Fuel/Engine Group
EVAP Carbon Canister, Solenoid, Hoses (leaks) Section 7, Section 14,
Fuel/Engine Group
221 "CHECK ENGINE" /"SERVICE ENGINE SOON"

liGHT ALWAYS ON OR NEVER ON
"CHECK ENGINE" /"SERVICE ENGINE
SOON" /"CHECK DCl" MESSAGE ON
NON-EEC 6.1 L/7.0L Heavy Duty Truck Check Engine Section 12
Light

ALL RIGHTS RESERVED
Diagnostic Routines
222 STATE EMISSION TEST FAILURE

NOTE: Canada and some states or metropolitan areas in the United States require
periodic Idle Emission Tests. All Ford products have. been designed to pass
these tests. If a Ford product fails an Idle Emission Test, it is probable that 1)
The engine temperature was not warm and stabilized prior to the test. 2) The
vehicle had idled excessively long prior to the test.
Prior to starting any repairs, complaints of Idle Emission Test failure should be verified.
The following example encompasses most of the emissions measurement modes of the current
state idle test procedures:
Ensure that the engine is at normal operating temperature and that all accessories are
turned off.
Read emissions at idle.
Run engine at 2500 300 rpm.
Read emissions within 30 seconds.
Return engine speed to idle.
Read emissions within 30 seconds.
If any emission components are replaced, Keep Alive Memory (KAM) should be cleared before
repeating State Emission Test procedure. Refer to Quick Test Appendix.

ALL RIGHTS RESERVED
Diagnostic Routines
222 STATE EMISSION TEST FAILURE

(CONTINUED)
MCU Componen~ Diagnostics Special MCU Diagnosis Manual
Ignition Scope Engine For: Spark Plug, Coil, Secondary Section 13, Ignition/Engine
Wires, Distributor Cap, Adapter and Rotor Group
Timing
Vacuum Distribution Vacuum Leaks/Blockage Visual and Audible
Carburetor Idle Mixture Section 4
Fuel Charging Assy/Throttle Curb or Fast Idle Speeds Visual, Section 4, Section 11,
Body/ External Carburetor Electrical and Vacuum Connections Fuel/Engine Group
Choke Pulldown
Bowl Vent
Internal Carburetors Idle, Air Bleeds or Fuel Passages Visual, Section 4, Fuel/Engine
Float/Inlet Needle and Seat Group
Fuel Delivery Injectors Section 11, Fuel/Engine Group
Fuel Rail
EGR Valve Section 6
Vacuum Regulator
PCV Valve Section 9
EVAP Carbon Canister, Purge Solenoid Section 7, Fuel/Engine Group
Thermactor Thermactor Air Dump Section 10
Exhaust Pipes, Muffler, Catalyst Section 5
Resonator, Heat Control Valve
Cooling Unstabilized Engine Temperature Visual, Routine 218
Basic Engine Scheduled Maintenance Engine Group
Compression
Valve Train
Camshaft

ALL RIGHTS RESERVED
Diagnostic Routines
223 IMPROPER SHIFT

(OASIS #5101, 5102)
Base Converter Clutch Control Solenoid Transmission Group
Transmission Converter Clutch
(E40D, A4LD, AXOD Electronic Pressure Control Solenoid
Only) Shift Solenoid # 1
Shift Solenoid # 2
4 X 4 Low Switch
(E40D, A4LD Only)
224 SHIFT INDICATOR LIGHT AND AUDIBLE

CHIMES "ON"
NOTE: VERIFY THAT THE CUSTOMER HAS READ THE OWNERS MANUAL ON THE NEW
3.8L SC OVERHEAT PROTECTION FEATURE.
The 3.8L SC is equipped with a Shift Indicator Light and Audible Chime that warns the
customer when the engine oil or coolant overheats while the vehicle is operated at high
speeds (above 100 mph) for extended periods of time. The Shift Indicator Light and Chime will
also warn the customer when the engine has reached too high an rpm for that gear. The
EECIV processor will reduce vehicle speed by limiting fuel to the engine when one of these
overheat conditions has been reached. The customer may then notice a loss of power and/or
a slight vibration. The Shift Indicator Light will "light" and the Audible Chime will produce a
"steady tone" to alert the customer to upshift at this time. Full power will be restored and the
Shift Indicator Light and Chimes will turn off when the vehicle returns to normal operating
temperatures.

EEC Shift Indicator Light Bulb Section 14
"SIL" Dimmer Relay
Top Gear Switch
3.8L SC Only Audible Chime System Thunderbird/Cougar
Shop Manual Section
33-50 - Warning Chimes

ALL RIGHTS RESERVED
SECTION 3
Emission Related
Components
Contents
PART
NAME NUMBER PAGE
Air Charge Temperature Sensor 12A697 3-1
Air Cleaner Cold Weather Modulator 9E862 3-2
Air Cleaner Temperature Sensor 9E607 3-3
Air Cleaner Vacuum Motor 90604 3-4
Barometric Absolute Pressure Sensor 9F479 3-5
Carbon Canister 90653 3-6
EGR Valve and Transducer Assembly 9H495 3-7
EGR Valve-Electronic 9F483 3-8
EGR Valve-Integral Back Pressure Transducer 90448 3-9
EGR Valve-Ported 90475 3-10
EGR Valve Position Sensor 9G428 3-11
Electronic Control Assembly (FBC/CFI/EFIISEFI) 12A650 3-12
EGR Vacuum Regulator 9J459 3-13
Engine Coolant Temperature Sensor ~ 12A648 3-14
Exhaust Heat Control Valve 9A427 .. .. .. ... .. ... .. .. .. 3-15
Feedback Carburetor Actuator Motor 9C908 .. .. .. ..... .. .. .. .. 3-16
Filter Assembly-Vacuum Vent 9F474 3-17
Fuel-Vapor Separator 9C369 3-18
Heated Exhaust Gas Oxygen Sensor 9F472 3-19
Ignition Barometric Pressure Switch 12A243 3-20
Emission Maintenance Warning (EMW) Module 12B514 3-21
Integral Relay Control Module 12B577 3-22
Knock Sensor 12A699 3-23
Manifold Absolute Pressure Sensor 9F479 3-24
Mass Air Flow Sensor ' ~ 128579 3-25
(Continued)

ALL RIGHTS RESERVED
SECTION 3
Emission Related
Components
Contents
PART
NAME NUMBER PAGE
Pressure Feedback Electronic EGR Valve 90460 3-26
Pressure Feedback Electronic EGR Transducer 9J640 3-27
Relay Assembly EEC (Power) Time Delay 12A646 3-28
Diode Assembly (Blade Type) 14A604 3-29
EEC Power Relay Location 12A646 3-30
Vacuum Check Valve 12A197 3-31
Vacuum Control Valve 8A564 3-32
Vacuum Delay Valves 9E897 3-34
Vacuum Harness Assembly-Nylon ; 9E498 3-36
Vacuum Regulator (2-Port) 9F490 3-38
Vacuum Regulator (3 & 4 Port) 9F490 3-39
Vacuum Reservoir. 9E453 3-40
Vacuum Restrictor 12A225 3-41
Vane Air Flow Meter 12B259 3-80

ALL RIGHTS RESERVED
Emission Related Components 31
TITLE BASIC PART NO. SYMBOL
Air Charge
12A697
Temperature Se~sor
I
DESCRIPTION
The sensor provides the Electronic Fuel Injection System with mixture (fuel and air)
temperature information. The ACT is used both as a density corrector for airflow calculation
and to proportion the cold enrichment fuel flow. This sensor is similar in construction to the
Engine Coolant Temperature (ECT) sensor, except it is packaged to improve sensor response
time.
The sensor is threaded into a. cylinder runn~r of the intake manifold and provides the fuel
strategy with mixture temperature inforr~ation. The sensor input is used as a density corrector
for airflow calculations and to proportion the cold enrichment f~el flow.
. .
4.9U5.0U5.8L TRUCK'
3.8L THUNDERBIRD/COUGAR
5.0L CAR APPLICATIONS
2.9L TRUCK APPLICATIONS
3.8L TAURUs/SABLE AND
CONTINENTAL AND
SUPERCHARGED
2.5L HSC CAR APPLICATIONS
(AT REAR OF INTAKE MANIFOLD)
3.0L CAR AND TRUCK
APPLICATIONS LOCATED IN THE
SIDE OF THROTTLE BODY
(UPPER INTAKE MANIFOLD)
1.9L ENGINE APPLICATIONS
IS LOCATED IN THE N1
INTAKE MANIFOLD
RUNNER
THREADED INTO INTAKE

MANIFOLD
A5783-H
Figure 1 Air Charge Temperature Sensor

(ACt)

ALL RIGHTS RESERVED
32 Emission Related Components
Air Cleaner Cold

Weather Modulator
9E862
I~CWM_
~
DESCRIPTION
A cold weather modulator is sometimes used in addition to the air cleaner temperature control
(bimetal) sensor to control the inlet air temperature.
The cold weather modulator traps vacuum in the system, so the door will not switch to cold
air when the vacuum drops during acceleration. The cold weather modulator only works when
the outside air is cold, (refer to the chart below).
TO DUCT VALVE
VACUUM MOTOR
A5918-B
Figure 1 Cold Weather Modulator
Functional Check
A 54 kPa (16 in-Hg) vacuum applied to motor side of the modulator holds or leaks as follows:
COLOR TYPE HOLDS LEAKS

Black N/O Below -6.7C (20F) Above 1.7C (35F)
Blue N/O Below 4.4C (40F) Above 12.8C (55F)
Green N/O Below 10C (50F) Above 24.4C (76F)
Yellow N/C Above 18.3C (65F) Below 10C (50F)

ALL RIGHTS RESERVED
Air Cleaner Temperat~re

9E607 0
Sensor
I- -
AICl
SIMET
DESCRIPTION
The sensor is installed in the cleaner tray or air cleaner line. and is subject to temperature
changes within the air cleaner. At a given increase in temperature, the sensor bleeds off
vacuum, permitting the vacuum motor to open the duct door to allow fresh air in while
shutting off full heat.
BIMETAL SENSOR
VACUUM MOTOR
FRESH AIR
IN
TO VACUUM SOURCE
Figure 1 Air Clea!1er Temperature Sensor
Functional Check
At an ambient temperature of less than 24C (75F), the sensor will allow vacuum to close
the duct door to fresh air. The sensor will bleed off vacuum to allow the duct door to open
and let in fresh air at or above the following temperatures:
Brown 24C (75F)

Pink, black, or red 32.2C H~OF)
Blue,. yellow or green 40.6C (105F)

ALL RIGHTS RESERVED
3-4 Emission Related Components
Air Cleaner
. .V. _a_c_u_u_m_M_o_t_o_r ..I...-
90604
----'
I
'--
@
~_~_L ___'
DESCRIPTION
The air. cleaner vacuum motor operates the door within the duct. which allows either warm or
cold air to enter the engine. depending upon the temperature within the air cleaner.
_n
:({( 0
~II I
I
I

A5921-8
Figure 1 Air Cleaner Vacuum Motor
Functional Check
When a vacuum of 27 kPa (8 in-Hg) or greater is applied to the vacuum motor. the door stem
should pUll up and stay as long as vacuum is applied to the vacuum motor.

ALL RIGHTS RESERVED
Emission Related Components 3-5
I----n---
L...-B_a_r_o_m_e_t_ri_C_A_b_S_O_lu_t_e a-.-...9_F_4_7_9---'
!ressure Sensor . ~
DESCRIPTION
The SAP Sensor measures barometric pressure using a frequency. This gives the EGA
information on engine load.
It is used as a barometric sensor for altitude compensation, updating the EGA during Key On,
Engine Off and every wide-open throttle.
The EGA uses SAP for:
Spark advance
EGR flow
Air/fuel ratio
VENT
A9387A
Figure 1 Barometric Absolute Pressure (BAP)

Sensor

ALL RIGHTS RESERVED
I~C_U_bo_n_c_~_~_~_r I~~II~~-O-la~o~o-~-_O~0-'1
DESCRIPTION
The fuel vapors from the fuel tank and carburetor fuel bowl are stored in the carbon canister
until the vehicle is operated. at which time. the vapors will purge from the canister into the
engine for consumption. There are two canister sizes. 925 ml and 1400 ml carbon. Canisters
are sometimes used in pairs when the vehicle has a large fuel tank or dual fuel tanks or dual
f
carburetor bowls.
~APORPUAGE
~CONNECTOAS
TYPICAL - OTHER
CONFIGURATIONS
ARE AVAILABLE
OUST CAP
OUST CAP VAPOR/PURGE NIPPLE
VAPOR NIPPLE \ FOAM FILTER
\ \ AND RETAINING
SCREEN
"SONICALLY RETAINING SCREEN AND SPRING

1400 ml CARBON CANISTER WELDED COVER 925 ml CARBON CANISTER
A6836F
Figure 1 Carbon Canisters
Functional Check
There are no moving parts and nothing to wear in the canister.
Check for loose. missing. cracked or broken connections and parts.
There should be no liquid in the canister.
NOTE: The Evaporative Emission System Is outlined In Section 7.

ALL RIGHTS RESERVED
TITLE
EGR Valve and Transducer

_A_s_~_m_b_~~~~~~~~~9_H_4_95~
BASIC PART NO. SYMBOL
--.
I~-~--' -~I
: ~
DESCRIPTION
The Valve and Transducer Assembly (9H495) which consists of a modified ported EGR valve
and a remote transducer, is used on selected engines (Figure 1). This assembly operates the
same as the Integral Back Pressure Transducer EGR Valve (90448) and is diagnosed and
serviced as an assembly only. Valve function checks are the same as those for the Integral
Back Pressure Transducer EGR Valve.
When servicing the assembly or any related vacuum harness, it is important to ensure proper
orientation of the transducer. The nipple 'of the transducer attached to the metal tube from the
EGR valve base must point straight down after installation. This allows drainage of exhaust
gas' condensation that may accumulate.
FROM CARBURETOR
Figure 1 EGR Valve and Transducer

Assembly
NOTE: Refer to Section 6, Exhaust Gas Recirculation (EGR) System.:

ALL RIGHTS RESERVED
EGR Valve-Electronic 9F483

I~
DESCRIPTION
The Electronic EGR Valve (Figure 1) is required in EEC systems where EGR flow is controlled
according to computer demands by means of an EGR valve' position (EVP) sensor attached to
the valve.
The valve is operated by a vacuum signal from the dual EGR Solenoid Valves (90474) or the
electronic vacuum regulator (9J459) which actuates the valve diaphragm.
As supply vacuum overcomes the spring load, the diaphragm is actuated. This lifts the pintle
off its seat allowing exhaust gas to recirculate (flow). The amount of flow is proportional to the
pintle position. The EVP sensor mounted on the valve sends an electrical signal of its position
to the Electronic Control Assembly (12A650).
The Electronic EGR Valve Assembly (9F483) is not serviceable. The EVP sensor (9G428) and
EGR valve (9H473) must be serviced separately.
EVP SENSOA~~-e--.......
9G428
EGR VALVE
AND SENSOR
ASSEMBLY
9F483
EGR VALVE
AND SENSOR
ASSEMBLY
EXHAUST GAS INLET 9F483
BASE ENTRY TYPE A7192-e
SIDE (EXTERNAL) ENTRY TYPE A71910C
Figure 1 Electronic EGR Valves
NOTE: Verify vacuum routing per the vehicle decal before proceeding to EEC-IV Quick
Test, Section 14.

ALL RIGHTS RESERVED
EGR Valve-Integral Back Pressure

Transducer
9D448
Ie
DESCRIPTION
The Integral Back Pressure Transducer EGA valve combines inputs of back pressure and EGA
port vacuum into one unit. The valve requires BOTH inputs to operate. The valve will not
operate on vacuum alone. The back pressure valve has two types; poppet and tapered pintle
(Figure 1).
VACUUM CHAMBER
~
~S~~~~!~~~ f"""V-A-CU-U-M-B-'-L-EE-D-H-O-L-E--VE-N-T""""'S
VACUUM TO ATMOSPHERE
~=1~~UNTILCLOSED BY EXHAUST
BACK PRESSURE WORKING
ON INNER DIAPHRAGM
~ ~ - -_ _ OPEN TO
EXHAUST ATMOSPHERIC
BACK PRESSURE PRESSURE
CHAMBER
ORIFICE
A7178-B
Figure 1 Integral Back Pressure Transducer EGR ..

Valve (9D448)
NOTE: Refer to Section 6, Exhaust Gas Recirculation (EGR) System.

ALL RIGHTS RESERVED
_E_G_R_V_a_lv_e_-p_o_rt_e_d ~9_D__.4~7-5-11--@-E-GR---
DESCRIPTION
The Ported EGR Valve is operated by a vacuum signal (only) from the carburetor EGR port
signal which actuates the valve diaphragm. As the vacuum increases sufficiently to overcome
the power spring, the valve is opened allowing EGR flow. The amount of flow is dependent on
the tapered pintle or the poppet position which is a direct result of vacuum signal (Figure 1).
OUTLET
VALVE INLET
(VALVE HAS TAPERED PINTLE ALSO)
BASE ENTRY, POPPET TYPE SIDE ENTRY, TAPERED PINTlE

A5978-C
Figure 1 Ported EGR Valve (90475)
NOTE: Refer to Section 6, Exhaust Gas Recirculation (EGR) System.

ALL RIGHTS RESERVED
---I
L.-E_G_R_V_81_v_e_P_OS_i_ti_o_D_S_eD_S_O_r_--I-..-"_9_G_4_2_S -----l I~--~-E-G-R

DESCRIPTION
The EVP Sensor provides EEC System with a signal indicating position of "the EGR valve.
EVP SENSOR
(REMOVABLE)
TYPICAL
LOCATION
ASSEMBLY
A5932D
Figure 1 EGR Valve Position (EVP) Sensor
NOTE: Refer to the EECIV Quick Test, Section 1~.

ALL RIGHTS RESERVED
Electronic Control Assembly 12A650 I

L.-(F_B_C_/_C_FI_/E_F_I/_S_EF_I_> ""'-- _
DESCRIPTION
The center of the EEC-IV system is a microprocessor called the Electronic Control Assembly
(ECA). The ECA (Figure 1) receives data from a number of sensors and other electronic
components (switches, relays, etc.). The ECA contains a specific calibration for optimizing
emissions, fuel economy, and driveability. Based on information received and programmed into
its memory, the ECA generates output signals to control various relays, solenoids and other
actuators.
The ECA in the EEC-IV system is a microprocessor like the one in the other EEC systems.
One significant difference is that this ECA has the calibration module located inside the ECA
assembly, unlike the EEC-III system.
The ECA is found in different locations, depending on the model. Refer to the chart for
locations.
PROCESSOR
ASSEMBLY - 12A650
Figure 1 Electronic Control Assembly (EGA)
Vehicle Location
Mark VII/Continental, Thunderbird/Cougar,
RH dash panel behind kick panel
Mustang, XR4Ti,
Ranger/Bronco II
Tempo/Topaz, Escort Under instrument panel left of steering column
Taurus/Sable Ahead of glove compartment
Lincoln Town Car, Ford Crown Victoria/Mercury
LH side dash panel in passenger compartment
Grand Marquis, Aerostar
F-Series/Bronco LH dash panel behind kick panel
Econoline RH dash panel under heater blower motor

ALL RIGHTS RESERVED
I~E_G_R_v_a_c_u_u_m_R_eg_U_I_a_to_r _ _.-..I--_9_J_4_5_9_11--~-,-~---
DESCRIPTION
The EGR Vacuum Regulator (EVR) is an electromagnetic device which controls vacuum output
to the EGR valve. The EVR replaces the EGR Solenoid Vacuum Vent Valve Assembly
(9D474). An electric current in the coil induces a magnetic field in the armature. The magnetic
field pulls the disk closed, closing the vent and increasing the vacuum level. The vacuum
source is manifold vacuum. As the duty cycle is increased, an increased vacuum signal goes
to the EGR valve.
A9359-A
Figure 1 EGR Vacuum Regulator

ALL RIGHTS RESERVED
Engine Coolant
12A648
Temperature Sensor 1_ _ _ _ _ _ _
DESCRIPTION
The Engine Coolant Temperature (ECT) Sensor (Figure 1) detects the temperature of engine
coolant and supplies the information to Electronic Control Assembly (ECA).
The ECT sensor is threaded into the heater outlet fitting or cooling passage on the engine.
For engine control applications, the ECT signal is used to modify ignition timing, EGR flow,
and air to fuel ratio as a function of engine coolant temperature. On electronic instrument
cluster applications, the ECT output is used to control a coolant temperature indicator.
3.8L TAURUS/SABLE
AND CONTINENTAL
-lA-----,~~'--_ 4.9U5.0U5.8L TRUCK

3.8L THUNDERBIRD/COUGAR/
SUPERCHARGED
(AT REAR OF CYLINDER HEAD)
(AT CENTER OF INTAKE MANIFOLD)
3.0L TRUCK INTAKE MANIFOLD
ADJACENT TO WATER OUTLET
(FRONT OF ENGINE) 3.0L CAR
REAR OF ENGINE
2.3L IS LOCATED IN THE WATER
OUTLET CONNECTOR AT
THE REAR OF THE
CYLINDER HEAD
THREADED INTO COOLING SYSTEM

A5937-G
Figure 1 Engine Coolant Temperature (ECT)

Sensor

ALL RIGHTS RESERVED
io-E_x_h_a_u_st_H_e_at_C_O_n_tr_o_I_V_a_lv_e_~9_A_4_2_7---, I~.--():[J-
-.,---
DESCRIPTION
The purpose of the Exhaust Heat Control Valve (Figure 1) is to divert hot gases from the
exhaust manifold to the intake manifold riser pad. Heat is transferred from the exhaust gas to
the riser pad, which in turn heats the incoming fuel! air charge. There are two types currently
available; the bimetal spring type and the vacuum actuated type.
Bimetal Type
Refer to Section 5 for a complete description.
Vacuum Operated
The vacuum operated heat valve functions as follows:
When the engine is started, the valve is closed by intake manifold vacuum acting on the
vacuum motor. .
The valve will stay closed until one of two conditions occurs:
1. When the engine coolant temperature reaches a predetermined value, the vacuum supply
to the heat valve is shut off by a temperature sensing vacuum switch and the heat valve
opens.
2. When the engine speed/load condition causes a drop in intake manifold vacuum below a
specific value, the heat valve opens.
A691 008
Figure 1 Exhaust Heat Control Valve
Functional Check
Apply 33.77-67.54 kPa (10-15 in-Hg) vacuum to the vacuum motor using a hand vacuum
pump, Rotunda 021-00014 or equivalent, and trap for 60 seconds. The valve must close and
not leak more than 6.75 kPa (2 in-Hg) and open when the vacuum is released. If it does not
operate in this manner, replace the valve.

ALL RIGHTS RESERVED
Feedback Carburetor
Actuator Motor
DESCRIPTION
9C908
1--
The Actuator (Figure 1) is part of the Carburetor Feedback Control System, used on 7200
model carburetors. The actuator is threaded into the carburetor body and its actuator shaft
moves a fuel metering pintle valve to produce a richer or leaner air/fuel mixture at the
carburetor. In response to an electronic signal coming from the Exhaust Gas Oxygen (EGO)
sensor and conditioned by the EEC (or MCU) System, the actuator shaft moves in and out.
PINTLE THREADED INTO
~URnoo
A6839-8
Figure 1 Feedback Carburetor Actuator Motor
Functional Check
1. Remove the FBCA motor from carburetor. Connect wiring harness to FBCA motor; turn
ignition switch to RUN to extend shaft. Turn ignition switch to OFF. If FBCA shaft does
not extend, replace FBCA motor and retest.
2. Push FBCA motor shaft back in by hand. If shaft will not push in, replace FBCA motor
and retest.
3. Remove and clean pintle valve, spring and carburetor passage with choke cleaner and a
small brush.
4. Reinstall pintle, spring a FBCA motor. Tighten FBCA motor to 8-10 Ib-ft.
5. Retest according to appropriate Quick Test. Refer to Section 14.
6. Check/reset curb idle, if necessary.
NOTE: FBCA motor Is partly diagnosed as a part of the 5.8l MCU electronic system.
Refer to the 5.8l FBC Police and Canadian Trailer Tow MCU Diagnosis Manual.

ALL RIGHTS RESERVED
TITLE' BASIC PART NO. SYMBOL
I -
~
Filter Assembly-
9F474
Vacuum Vent
- VREST FLTR
DESCRIPTION
The Vacuum Vent Filter (Figure .1) is used to filter air being drawn into the vacuum system
when a vacuum bleed is required. It is a nylon tee with a restrictor and an open cell foam on
one leg.
~
-
. _
RESTRICT';" { BLUE .015" (E~E-9F4~4-AA)
RED _.... (E3EE-9F<74-8A)
. . OPEN CELL FOAM .
A7117-8
Figure 1 Vacuum Vent Filter Assembly
NOTE: If the filter appears to be dirty, wash it in an appropriate solvent.

ALL RIGHTS RESERVED
I_F_u_e_I-_v_a_p_o_r_S_e_p_a_ra_t_o_r -""--_9_C_3_6_9--l11 ~_SA_.FA

_ _____'
DESCRIPTION
The Fuel-Vapor Separator (Figure 1) is used in vacuum systems to prevent fuel migration to a
vacuum operated device.
-.
W H l T E - -
~t:::=:;-il
l. ~-: ...
-.-
e-
.J
TO VACUUM DELAY
VALVE OR
DISTRIBUTOR
(HIGH SIDE)
~
AS285-C
Figure 1 Fuel-Vapor Separator
Functional Check
NOTE: Separator requires positive orientation to ensure that any fuel collected will drain
back to the carburetor.
If separator becomes cracked or clogged, replace the separator.

ALL RIGHTS RESERVED
Heated Exhaust Gas

9F472
Oxygen Sensor
DESCRIPTION
The 'Heated Exhaust Gas Oxygen Sensor (HEGO) (Figure 1) supplies the ECA with a signal
which indicates a rich or lean condition during. engine operation.
THREADED INTO LH
~{L==;;=~--EXHAUST PIPE ON
3.8l TAURUS/SABLE
TYPICAL AND CONTINENTAL
LOCATIONS
THREADED INTO EXHAUST MANIFOLD ON 2.3l, 3.8L SUPERCHARGED,

5.0L SEFI (BOTH SIDES)
THREADED INTO CROSSOVER BOSS TUBULAR RUNNER ON 1.9L EFI
THREADED INTO EXHAUST MANIFOLD ON 1.9L CAR. 49U5.0U58L
TRUCK -
THREADED INTO CENTER REAR OF EXHAUST MANIFOLD ON 2.3L HSCI
2.5L HSC
THREADEDINTO V-PIPE JUNCTURE OF CATALYST INLET ON 3.0l EFI
A7752-E
Figure 1 Typical Heated Exhaust Gas

Oxygen Sensor (HEGO)

ALL RIGHTS RESERVED
Ignition Barometric
Pressure Switch
DESCRIPTION
12A243
1---
The Ignition Barometric Pressure Switch (Figure 1) is used to control spark timing and/or other
electrical devices in response to changes in barometric pressure (Le., altitude). When
controlling spark timing, the ignition module (12A244) is made to vary the spark timing by an
amount determined by calibration resistors in the switch assembly. In normal operation, spark
timing is increased for vehicle operation above the switching point (increasing altitude) and
retarded for vehicle operation below the switching point (decreasing altitude). When controlling
other electrical devices, only On/Off control is provided; with On (switch closed) above the
switching point and Off (switch open) below the switching point. Some switch assemblies
control both spark timing and another device (dual switch assembly) and other switch
assemblies control only one or the other (single switch assembly).
A7757-8
Figure 1 Ignition Barometric Pressure Switch
Dual switch assembly shown.
Attaching brackets vary according to installation requirements.
Connectors may vary.
Resistance (Ohms) Resistance (Ohms)

Part Number Below 3,000 Feet Above 4,600 Feet
E2AE-12A243-AA Greater than 200,000 Less than 1
E43E-12A243-AA 2,820-2,920 1,750-1,850
E4DE-12A243-AB 2,5602,660 1,960-2,060
E4EE-12A243-AA Greater than 200,000 Less than 1
Either resistance value is correct if altitude is between 3,000 and 4,600 feet.

ALL RIGHTS RESERVED
Emission Related Components
TITLE
Emission Maintenance Warning

(EMW) Module
BASIC PART NO.
128514 1------
SYMBOL
DESCRIPTION
The Emission Maintenance Warning (EMW) Module (Figure 1) is mounted in the instrument
panel. The EMW function activates the Check Engine Light {CELl .on the instrument panel at
2,000 hours (60,000 miles). The light indicates the emission maintenance should be performed.
3 PIN MODULE
...----
' " U0 A11623A
Figure 1 Emission Maintenance Warning (EMWj Module
NOTE: Refer to Section 12 for Pinpoint Testing.
APPLICATIONS:
PART NUMBER ENGINE VEHICLE MODULE

E5TF128514-AA 6.1 L, 7.0L F, B, Series Heavy Truck EMW

ALL RIGHTS RESERVED
TITLE
Integral Relay Control Module

BASIC PART NO.
128577 1------
SYMBOL
DESCRIPTION
The Integral Relay Control Module (IRCM) (Figure 1) interfaces with the EEC-IV to provide
control of the cooling fan, A/C clutch and the fuel pump. The module also incorporates the
EEC power relay to provide power to the EEC-IV system.
The module is designed specifically for underhood application. The limits of operation are as
follows:
Operating Temperature - 30C to 100C

Storage Temperature - 40C to 125C
Operating Voltage 7 to 17 volts
o
A9861-B
Figure 1 Integral Relay Control Module
8racket and
Powertraln Model Control Assembly
Application Controller -128577- -128581- Vehicle Location
2.5L HSC A/T
Taurus/Sable E9DF-BB E9DF-BB Radiator Support
3.0L A/T
Taurus/Sable E9DF-DB E9DF-DB Radiator Support
3.0L SHO E9DF-AB E9DF-DB Radiator Support
3.8L Supercharged E9SF-AB E9SF-AB Radiator Support
3.8L A/T
Taurus/Sable E9DF-EB E9DF-EB Radiator Support

ALL RIGHTS RESERVED
11---'
IKnock Sensor 12A699
DESCRIPTION
The Knock Sensor (Figure 1) is a piezoelectric accelerometer with the sensor designed to
resonate at approximately the same frequency as the engine knock frequency. The sensor
uses the resonant frequency to mechanically amplify the vibrations. This method allows
relatively large signals to be achieved without electrical amplification and with small package
size.
The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal
diaphragm. Electrical connections are made through a two pin integral connector.
A7188-8
Figure 1 Knock Sensor
Part Resonant
Number Frequency Color Planned Usage Thread
E3AF-AA 5.4K Black 5.8L Ford/Mercury 1/2-13 UNC

E6TF-AA 6.45K Black 2.9L Ranger/Bronco II M10 X 1.5mm-6g
E5TF-BA 6.0K Black 3.0L Taurus/Sable, Aerostar M10 X 1.5mm-6g
E9TF-AA 9.5K White 4.9L 5.0L/5.8L Econoline/Bronco M12 X 1.5mm-6g
E9SF-AA 5.7K Gray 3.8L Supercharged T-Bird/Cougar M10 X 1.5mm-6g
E3SF-AA 5.7K Gray 2.3L OHC Mustang - M12 X 1.5mm-6g
E5TF-AA 6.0K Black 3.0L SHO Taurus M10 X 1.5mm-6g

ALL RIGHTS RESERVED
L..-M_aO_i_f_OI_d_A_b_S_O_lu_t_e_p_r_e_s_s_u_re_--,--_9_F_4_7_9----1
_Sensor .
Ir-----Yn----
DESCRIPTION
The MAP sensor (Figure 1) measures manifold vacuum using a frequency. This gives the EGA
information on engine load.
It is used as a barometric sensor for altitude compensation, updating the EGA during Key On,
Engine Off and every wide-open throttle.
The EGA uses MAP for:
Spark advance
EGR flow
Air/fuel ratio
MAP SENSOR
INTAKE
MANIFOLD
VENT A9384-A
Figure 1 Manifold Absolute Pressure Sensor

ALL RIGHTS RESERVED
Emission .Related Components 325
TITLE
IMass Air Flow Sensor

BASIC PART NO.
128579 11-----------
SYMBOL
DESCRIPTION
The sensor directly measures the mass of the air flowing into the engine. The sensor output
is a D.C. (Analog) signal ranging from about 0.5 volts to 5.0 volts used by the ECA to
calculate the injector pulse width for stoichiometry. The sensing element" is a thin platinum wire
wound on a ceramic bobbin and coated with glass. This "hot wire" is maintained at 200C
above ambient temperature'as measu~ed by a constant "cold wire".
MASS AIR FLOW

SENSOR
HOT WIRE
SENSOR
COLD WIRE
SENSOR
.......
AIR
. FLOW
A9389-B
Figure 1 Mass Airflow Sensor Assembly

ALL RIGHTS RESERVED
Pressure Feedback Electronic Ir----~------,

",-E_G_R_V_al_v_e ---'-_9.D_4_6_0----' ~
DESCRIPTION
The Pressure Feedback Electronic (PFE) EGR valve is a conventional ported EGR valve. The
valve is used in conjunction with a pressure transducer (9J460) which supplies pressure
feedback to the EEC-IV processor. The EGR flow rate is proportional to the pressure drop
across a remotely located sharp edged orifice.
.\9362.\
Figure 1 Typical Pressure Feedback

Electronic EGR Valve

ALL RIGHTS RESERVED
p_r_e_s_su_r_e_F_ee_d_b_a_c_k_E_le_c_tr_o_D_i_C_ _9_J_4_6_0---,
EGR Transducer
I~---m
o-W
P
----
EF
.....
DESCRIPTION
The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure
signal into a proportional analog voltage wh~ch is digitized by the EEC-IV processor. The EEC-
IV processor uses the signal received from the PFE transducer to complete the optimum EGR
flow. , ' ,
Af363.A
Figure 1 Pressure Feedback Electronic EGR

Transducer

ALL RIGHTS RESERVED
Relay Assembly EEC (Power)

12A646
EEC (Power) Time Delay 1 _
DESCRIPTION
There are three types of relays: the STO Power Relay, the Time Delay Power (TOP) Relay
and ISO Power Relay. The TOP has a delay of 5 to 10 seconds and is used with an actuator
assembly throttle control. STO Power Relay and TOP relay types consist of a movable contact
in the normally open position (SPST). Where as ISO Power Relay is SPOT. All STO power
relays (except time delay) have the same design with a different bracket attachment. ISO
Power Relay is the same as fuel pump and WAC Relays and have different base part
numbers.
Function
EEC power relays are in parallel with the ignition switch and provides power to the EEC, STO
and Time Oelay module. TOP relays also provide reverse battery protection with internal diode
and increased load handling to improve ignition switch reliability, where as ISO Power Relay is
connected in series with separate stand alone diode, which provides reverse battery protection.
Time Delay Power

Specifications STD .Power Relay ISO Power Relay
Relay
Pull-in Voltage 9V DC max 8.5V DC max 5-9V DC max
Millivolt Drop 15 my/amp 10 my/amp 5 my/amp
Coil Current 220 rna @ 14.4V DC 220 rna @ 12.8V DC 220 rna @ 12.8V DC
Drop-out Voltage 4.5V DC 1-4V DC 1.2V-4V DC
1. KEY POWER (RUN AND CRANK) 1. TO BATIERY NEG. POST
2. TO BATIERY NEG. POST 2. KEY POWER (RUN AND CRANK)
3. V POWER TO EEC MODULE 3. V POWER TO EEC MODULE
4. TO BATIERY POS. POST 4. TO BATIERY POS. POST
EEC POWER (TIME OELAY) RELAY STO EEC POWER RELAY
87 t:=::::::l
87. V POWER TO EEC MODULE
D~D
30. BATIERY POSITIVE POST
86 0 30
85
86. TO DIODE CATHODE
85. BATIERY NEGATIVE POST
87A. NOT CONNECTED

An58~E
ISO RELAY
Figure 1 Relay Assembly

ALL RIGHTS RESERVED
Emission Related. Components 3-29
__D(Blade
_i_O_de_A_s_se_m_bl_
Type)
Y
--&....-1_4_A_6_0_4---' . 1------kJ------
DESCRIPTION
The Device is 1 amp, 400V min. glass passivated metalurgically brazed, low leakage rectifier
diode.
Function
The diode' is in series with ,EEC power relay coil and provides reverse battery protection.
- . .
Specifications
Forward Volt~ge VF O.BOV @ IF = 10ma; 1.15V @ IF = 1.0 A
-Reverse Current
"-
.I R 100ma- @ VR == 400V; 20ma @ VR = 10V .

Reverse Breakdown Voltage VR 400 @ IR = 10.0nA
. .
~
OP
. ~lOAELAYCOIL VIEW
BOTTOM
V~W
0 KEY PWA (RUN & CRANK)
.
DIODE
A13533-A
Figure 1 Diode Assy
.. 'Part Number System Locat,lon(s) Location(s)

FOVF-14AG04-AA Ford/Mercury 5.0L SFI Engine Compartment Relay Box,
" Lincoln -Town Car 5.gL SFI ~ttachedto vacuum reservoir.
-.

ALL RIGHTS RESERVED
3-30 Emis"sion Related Components
I~-
EEC Power
12A646
Relay Locations
EEC POWER RELAY LOCATION AND APPLICATIONS
PART NUMBER AND RELAY

SYSTEM APPLICATION(S) LOCATION(S)
TYPE (Power or Time Delay)
E6EF-12A646-B1A/B2A Escort/Lynx EXP 1.9L EFI Passenger compartment under
Power Relay (Std.) dash on m0dule bracket.
E3UF-12A646-B1A/B2A Mustang 2.3L OHC/5.0L SFI Passenger compartment on module
Power Relay (Std.) bracke! in right cowl area.
E3EF-12A646-B1A/B2A Tempo/Topaz 2.3L HSC EFI Passenger compartment under
Power Relay (Std.) 2.3L HO dash behind glove compartment
E3AF-12A646-B1A/B2A Thunderbird/Cougar 3.8L EFI Engine compartment fuse/relay
Power Relay (Std.) box
Ford/Mercury 5.0L SFI Engine compartment doghouse.
Lincoln Town Car 5.0L SFI
Mark VIII 5.0L SFI
Ranger/Bronco II 2.3L/2.9L
Aerostar 3.0L EFI
Econo/F-Series/Bronco
4.9L/5.0L/5.8L
F-Series/Bronco 7.0L
Econoline/F-Series/Heavy
Truck 7.5L/7.3L
E7EF-12A646-A1A Power Escort/Lynx/EXP 1.9L CFI Passe.nger compartment under
Relay (Time Delay) dash on module bracket.
FOVB-9345-AA Power Relay Ford/Mercury 5.0L SFI Engine compartment relay box;
(ISO) Lincoln Town Car 5.0L SFI attached to vacuum reservoir.

ALL RIGHTS RESERVED
I_v_a_c_uu_m__"C_h_e_C_k_v_a_l_ve_" ....Io..-l_2_A_l_9_7 11""'--_ _ ~_vc_K-_v _
DESCRIPTION
A Vacuum Check Valve (Figure 1) blocks airflow in one direction. It allows free airflow in the
other direction. The check side of this valve will hold the highest vacuum seen on the vacuum
side. If not, replace it.
- - - - DIRECTION OF FREE AIRFLOW
~*~ VACUUM SIDE

- BLACK
AIOI7oC
Figure 1 Vacuum Check Valve
Functional Check
Apply 54 kPa (16 in-Hg) vacuum to "check" side of valve and trap. If vacuum remains above
50.6 kPa (15 in-Hg) for 10 seconds, the valve is acceptable.

ALL RIGHTS RESERVED
'01]
8A564 2PORT
~ ogv
3PORT
Vacuum Control Valve 9D473

9F454
12A091 vCv
DESCRIPTION
The VCV controls vacuum to other emission devices during engine warm-up: the 2-port types
simply open when engine coolant reaches their pre-determined calibration temperatures; the
4-port types open likewise, since they are nothing more than two 2-port types in one housing;
and the 3-port types switch the vacuum source to the center port from the top or the bottom
ports. Electrical switches can be either open or closed until the VCV is fully cycled. Most
VCV's respond to a sensing bulb immersed in engine coolant by utilizing a wax pellet principle.
The only exception is the 9F454 which operates on a bimetal principle. Vacuum is usually
sourced as illustrated in Figure 1.
r--~- A
8AS64 8
OR
12A091
0
A , EGR VALVE
A
M
8, VACUUM SOURCE A
B
B 9F4S4
E A2 CARBON CANISTER
PURGE VALVE
S 8 VACUUM SOURCE
2
90473
A CONNECTS TO VACUUM DEVICE
B CONNECTS TO VACUUM SOURCE
A6064-D
Figure 1 2-, 3-, and 4-Port Vacuum Valves

ALL RIGHTS RESERVED
Emission Related Components 3..33
8A564
Vacuum Control Valve 9D473
9F454
12A091
Functional Vacuum Check
1. With a cold engine, passag~. A to B should be closed and passage A to C should be

open.
2. With engine" at normal operating temperature, the VCV should be open between A an'd B
and closed betWeen A and C. '. . " .'"
For the 4-port valve, check A 1 to B1 and A2 to B2 separately.
3. If these conditions are not met, replace the VCV Valve.
Electrical Vacuum S'witch
The electrical vacuum switch (Figure 2) could be either opened or closed at room temperature.
It will be reversed (opened to closed or closed to opened) with the engine at full operating,
temperature.
C (SPARK PORT VACUUM)

--;:? NOAMALLY OPEN ~
/ A COMMON PORT
"-.. (DISTRIBUTOR)
~ NORMALLY CLOSED
B (INTAKE MANIFOLD) .
A615O-C
Figure 2 Electrical Vacuum Switch - 8A564
Functional Electrical Check
1. While the engine is cold,' measure the continuity across the switch. Compare with
specifications.
2. Warm the engine to normal operating temperature.
3. Measure the continuity across the switch. Compare '!"lith specifications.
4. The vacuum function is checked as previously described.

ALL RIGHTS RESERVED
9E897
Vacuum Delay Valves 12A189 ~ <>IJo
12A208 VDV ot==Ifo VROV
12A245 OVTW
DESCRIPTION
Vacuum Delay Valves (VDV) are used for a gradual application or release of vacuum to a
vacuum-operated device to help control emissions. The four valves currently in use are
illustrated below with an arrow to show the direction in which airflow is restricted (Figure 1).
Note that, although each valve is named for a given system application, it may be used .
elsewhere.
TO THERMACTOR
(LARGE PORT)
-H---++~ RESTRICTED AIRFLOW .-!=~+-R-~
"'_-.!
. VACUUM .....
SOURCE
(SMALL PORT)
WHITE
SIDE
ALTERNATE
THERMACTOR OR AIR CLEANER DESIGN
RETARD DELAY VALVE 9E897 TWO-WAY DELAY VALVE-12A245
VACUUM -;(HI_---IIH1~ RESTRICTED_---,..+-;-.....;.-;--+-+-.

SOURCE AIRFLOW
L
DISTRIBUTOR
COLOR SIDE ALTERNATE

DESIGN
WHITE SIDE
DISTRIBUTOR RETARD DELAY

SPARK DELAY VALVE-12A189 VALVE-12A208
Figure 1 Four Types Of Vacuum Delay Valves

ALL RIGHTS RESERVED
9E897
Vacuum Delay Valves 12A189 e>I}<> <>RJo
12A208 VDV ~ VRDV
12A245 DVTW
Functional Check
Connect a hand .vacuum pU'mp,' Rotunda 021-00014 or equivalent,' to the VDV as shown in
Figure 2 and pump.
c3D=~----.I@ ~
VDV HOSE
PUMP
Figure 2 Hand Vacuum Pump Connection
1. Valves with one side black or white and the other side colored are good if vacuum' can
be built-up in one direction, but not the other direction and if that built-up vacuum can be
seen to slowly decrease. '
2. Valves with both sides the sam.e color are good if vacuum can be built-up in both
directions before visibly decreasing.
NOTE: .Exercise care in order to prevent 011 or dirt from getting into the valve.

ALL RIGHTS RESERVED
L..--...v_ac_u_um_"_ar_oe_s_s
~embly - Nylon _~ 9_E4_9_8-----1 I-~-l-d-+-I-'~-I
. ~l) .
DESCRIPTiON
Engine vacuum systems currently use a preassembled harness which features colored nylon
vacuum lines. The color is a visual aid both in production and in service. The emission decal
on the engine provides a colored schematic of the vacuum hook-up which corresponds with
the preassembled harness."
Vacuum hose harnesses (Figure 1) consist of nylon -hoses; O.150-inch outer diameter and
O.OeO-inch inner diameter bonded to nylon or rubber connectors. Occasionally, a rubber hose
may be connected to the harness. The nylon connectors have rubber inserts to provide a seal
between the nylon connector and the component connection (nipple).
387065-8
3838478
387043-8 383013-8
373846-8 384111-8
A7115-8
Figure 1 Vacuum Connectors Used With 5/32 Inch Rubber Hose for Service

ALL RIGHTS RESERVED
Vacuum Harness
Assembly - Nylon
SERVICE PROCEDURES
.9E498
1--
If a nylon tube is broken or kinked, and the damaged area is 1/2-inch or more from a
connector; the tube can be repaired by cutting out the damaged section, but not more than
1/2-inch, and then installing a rubber union (Figure 2).
j t ~~i~~~:,g~
1I2-INCH
Of UNION
~t=:=~' ===::=::::34
" " KINK OR HOLE
ORIGINAL IN NYLON HOSE ORIGINAL
~_38~1_4\3-_S_~~~
... a
CUT OUT DAMAGED AREA

AND INSTALL UNION
REPAIR
A7196-B
Figure 2 Broken or Kinked Hose Repair Figure 3 Hose Replacement
If the remaining hose is too short or the damaged portion is more than 1/2-inch: replace the
entire hose and connectors with rubber vacuum hoses and a tee. Use existing service stock
of 5/32-inch hose, 7/32-inch hose and' tees.
NOTE: Circled numbers shown in Figure 3, identify same connection points on both
original and repaired harnesses. .
i CAUTION 1
Care must be exercised to keep all vacuum parts away from hot components such as
EGR tubes and exhaust manifolds. In addition, holes may be worn into the nylon hoses
if allowed to rub against rough surfaces.

ALL RIGHTS RESERVED
Vacuum Regulator (2-Port) 9F490

I~_~_I
DESCRIPTION
The two port vacuum regulator (Figure 1) provides a constant output signal when the input
signal is greater than a preset level. At a lower input vacuum, the output equals the input.
VACUUM INPUT _ _-...

SIGNAL
AU41-8
Figure 1 2-Port Vacuum Regulator
Functional Check
1. Remove vacuum line from the barbed output port (Figure 1), and install Rotunda Vacuum
Gauge 059-00008 or equivalent.
2. With manifold vacuum at the input port and the engine at idle, the vacuum gauge should
read between 35.7-45.9 kPa (10.5-13.5 in-Hg).
3. If the vacuum gauge reading is not within the specification, replace the regulator as
required.
NOTE: The two port vacuum regulator Is commonly attached to a 90-cubic inch vacuum
reservoir.

ALL RIGHTS RESERVED
~-
Vacuum Regulator
9F490
(3 & 4 Port) I_ _
DESCRIPTION
The Three-Port (Figure 1) and Four-Port (Figure 2) regulators are used to control the vacuum
advance to the distributor. During engine idle conditions, the manifold vacuum signal is reduced
to a constant output signal. Off idle, the output signal equals the spark port.
SPARK PORT
COLOR CODE CAP

A5970-8
A5971-8
Figure 1 3-Port Vacuum Regulator Figure 2 4-Port Vacuum Regulator
Functional Check
1. Remove the vacuum line from distributor port and install a vacuum gauge,
(Figures 1 and 2).
2. With the engine at idle, the vacuum gauge reading shouldbe within 3.4 kPa (1 in-Hg)
vacuum of calibration point. .
3. With the color codes different, vacuum readings are identified:
Black is 20 kPa (6 in-Hg)
Green is 23.6 kPa (7 in-Hg)
Red is 27 kPa (8 in-Hg)

If the color code does not meet the respective vacuum reading, replace as required.
NOTE: This procedure is applicable to both types of' vacuum regulators.

ALL RIGHTS RESERVED
IVacuum Reservoir 9E453

VAESEA
-~
VRESER
DESCRIPTION
The Vacuum Reservoir (Figure 1) stores vacuum and provides "muscle" vacuum. It prevents'
rapid fluctuations or sudden drops in a vacuum signal such as those seen during an
acceleration period.
VACUUM
OUTPUT
WITH CHECK VALVE

A6069C
Figure 1 Vacuum Reservoirs
Functional Check
When charged initially with 15 to 20 in-Hg vacuum, vacuum loss shall not exceed .5 in-Hg in
60 seconds. If it does, replace the reservoir.

ALL RIGHTS RESERVED
TITLE BASIC PA~T NO. SYMBOL
12A225
Vacuum Restrictor'
.9K319 ~'T
V REST L REST TREST
DESCRIPTION
This orifice-type flow restrictor (Figure 1) is used in several' emission calibrations to control the
flow rate and/or timing inactions to the following emission component systems:
a. EGA valve timing - opening and closing
b. Part throttle spark advance
c. Purge system
d. Therma<?tor system
RESTRICTOR HOLE SIZE COLOR

.015 IN. BLUE
.020 IN. RED
.024 IN. ORANGE
.030 IN. YELl.OW
.060 IN. GREEN
A6068-C
Figure 1 Distributor Vacuum Restrictor .
The flow rate through the restrictor is ~he same in both directions. .If it is blocked, replace it.

ALL RIGHTS RESERVED
342 Emission Related' Components
IVane Air Flow Meter 128529 II~---------

DESCRIPTION
The Vane Air Flow Meter (Figure 1) measures air flowing into the engine and is mounted
between the air cleaner and the air throttle body assembly. The meter contains a movable
vane directly connected to an electrical device known as potentiometer. Air, rushing through
the Vane Air Flow Meter, changes the position of the vane and the potentiometer. The
potentiometer relays vane position information to the EEC-IV module. The EEC-IV module can
then translate vane position information into the volume of air flowing into the engine.
Inside the Vane Air Flow Meter is an air temperature sensor. This sensor constantly monitors
the temperature of the air flowing into the engine. This information is also transmitted. to the
EEC-IV module.
The EEC-IV module computes volumetric airflow and air temperature, then adjusts the fuel flow
to obtain the optimum air/fuel mixture.
AIRFLOW
A7183-8
Figure 1 Vane Air Flow Meter

Functional Check
1. Use the Shop Manual for the Vane Air Flow Meter removal procedure.
2. After removing the Vane Air Flow Meter, spray carburetor cleaner on a clean cloth and
pass the cloth through the meter to remove oil film buildup. Do not spray inside the Vane
Air Flow Meter.
3. Reinstall the Vane Air Flow Meter.
4. Rerun Quick Test. Refer to Section 14.
5. If code is still present, replace Vane Air Flow Meter. Rerun Quick Test.

ALL RIGHTS RESERVED
SECTION 4
Carburetors,
Throttle Bodies and Injectors
Contents
Component Descriptions 4-1
DC Motor-Idle Speed Control Actuator .4-1
Idle Air Bypass Valve Assembly .4-2
Air Throttle Body Assembly .4-3
CFI, EFI & Carburetor System Diagnosis By Symptom .4-4
Throttle Body and Idle Air Bypass Valve Assembly

Cleaning Procedure 4-19
Idle Setting Procedures

For 3.0L Probe, all 4.9L and 5.8L (U/8500 GVW) 4-20
Idle Speed Setting Procedures: 4-22
Idle Mixture Setting Procedures 4-37
Cold Enrichment System 4-38
Choke Adjustment Procedure

6.1 Land 7.0L Engines Truck, Over 8500 GVW 4-51
Fuel Injector Testing/Cleaning 4-52
Fuel Injector Tester/Cleaner 4-55
EFI Injectors : 4-59

ALL RIGHTS RESERVED
Carburetors, Throttle Bodies and Injectors 4-1
Component Descriptions
DC Motor-Idle Speed Control Actuator - 9N825

The DC-Motor Idle Speed Control Actuator (DC-ISCA) (Figure 1) is mounted to the fuel
charging assembly and controls the idle speed incJudi~g such functions as: high cam rpm, anti-
diesel shutoff, dashpot and pre-positioning for next vehicle start. The DC-ISCA is driven by the
EEC-IV system and includes an integral Idle Tracking Switch (ITS).
AnS3-B
Figure' 1 DC Motor-Idle Speed Control Actuator
APPLICATIONS
PART NUMBER ENGINE VEHICLE

E90F-9N825-AA 2.5L HSC Passenger Car
E8DF-9N825-AA 1.9L CFI Passenger Car

ALL RIGHTS RESERVED
42 Carburetors, Throttle Bodies and Injectors
Component Descriptions
Idle Air Bypass Valve Assembly - 9F715
The Air Bypass Solenoid (Figures 2 and 3) is used to control engine idle speed and is
operated by the Electronic Engine Control (EEC) module. .
The valve allows air to pass around the throttle plates to control:
Cold engine fast idle
No touch start
Dashpot
Over temperature idle boost
Engine idle load correction
VALve
BODY
SOLENOID INLET
(ATMOSPHERE)
.,
OUTLET
(MANIFOLD VACUUM)
A12784-A
Figure 2 Hirachi Idle Air Bypass Valve Assembly
AIR AIR
OUT IN
(MANIFOLD) (ATMOSPHERE)
A12765.A
Figure 3 Nippendenso Idle Air Bypass Valve Assembly

ALL RIGHTS RESERVED
Carburetors, Throttle Bodies' and Injectors 43
Component.Descriptions
Air Throttle Body Assembly - 9E926
The Throttle Body Assembly (Figure 4) controls airflow to the engine through a single or dual
butterfly valve. The throttle pgsition is controlled by convention~1 linkage. The body is a single-
piece, die casting of aluminum. It has a single bore with an air bypass channel around the
throttle p l a t e . .
Other features of the Air Throttle Body Assembly include:
1. An adjustment screw to set the throttle plate stop 'at a minimum idle airflow position.
2. A pre-set stop to locate the wide-open throttle (WOT) position.
3. A throttle body mounted throttle position sensor (may be mounted elsewhere).
4. A PCV fresh air source upstream of the throttle plate (some applications).
5. Individual vacuum taps for PCV and EGA control signals (some applications).
6. Idle air bypass valve (some applications).
A6988-8
Figure 4 Typical Air Throttle Body Assembly, Maybe of Single or Dual Bore Type

ALL RIGHTS RESERVED
CFI, EFI & Carburetor System Diagnosis By Symptom
Driveability Symptom Index

Page
Cranks Normally But Won't Start Hot/Cold 4-5 & 4-9
Starts Normally But Won't Run (Stalls), Hard Start Hot/Cold 4-6 & 4-10
Cranks Normally But Slow to Start, Hard Start Hot/Cold 4-6 & 4-10
Rough Idle Hot/Cold 4-7 & 4-11
Misses Under load 4-14, 4-15 & 4-16
low Idle Speed, Stalls on Deceleration or Quick Stop 4-13
Hesitates or Stalls on Acceleration 4-8 & 4-12
Backfire (Induction or Exhaust) 4-5, 4-6, 4-8 & 4-10
Lack of Power 4-14 & 4-16
Surges at Steady Speed 4-17
High Idle Speed, Engine Diesels 4-18
Poor Fuel Economy 4-15
Exhaust Smoke - Black, Flooding 4-17
Gas Smell 4-17
Emission Test Failure 4-7, 4-11 & 4-17
Pre-checks
Verify battery is fully charged.
Verify adequate fuel supply in the fuel tank.
Verify fuse/fuse link integrity.
Inertia switch set.
Inspect the fuel lines and fuel tank for deformaties, leaks and kinks.
Inspect the vacuum lines for leaks - disconnected, kinks, or broken plastic connector.
Inspect the cooling system to be sure it is filled and free of leakage.
Inspect the cooling hoses to be sure they are not collapsed, kinked, or leaking.
Inspect ignition system for crossfire, spark plug wires - coil wire off or loose.
Inspect ignition system for breakage or other damage.
Verify ignition timing.

ALL RIGHTS RESERVED
Carburetors, Throttle Bodi~s and. Injectors 4-5
SYMPTOM SYSTEM POSSIBLE SOURCE ~CTION

No Start - Cold Carburetor No fuel in carburetor bowl. Check by actuating accelerator
pump. If no fuel discharge is seen,
Backfire check fuel delivery system. Refer
(Induction or to Fuel/Engine Shop Manual
Exhaust) Group or Section 11.
Cold enrichment or choke system Check linkage for proper operation
not functioning. and adjustment clean, service, or
replace as required.
Venturi valve sticking open, 7200 Clean 'and service as required.
only.
Clogged air bleeds or idle Clean with solvent and compressed
passages. air.
CFI/EFI Inoperative ISC motor. Go to EEC-IV Diagnostics.
TP sensor stuck at WOT Crank engine with TP sensor
disconnected.
Plugged, leaking, or inoperative CFI only - Check for fuel
injector. discharge at the injector.
Insufficient fuel pressure. CFI/EFI- Refer to Section 11 for
Electric Fuel Delivery Systems.
EFI only - Go to Fuel Injector
Testing/Cleaning procedure, Page
4-19.
Throttle body ISC-BPA Clean throttle body and ISC-BPA.
contaminated. Refer to Fuel/Engine Shop Manual
Group.
Throttle plate stop screw backed Go to adjustment procedure in this
out. Section.
~
Return to Routine 201, Section 2.

ALL RIGHTS RESERVED
4-6 Carburetors, Throttle Bodies and Injectors
SYMPTOM SYSTEM POSSIBLE SOURCE ACTION

Hard Start - Cold Carburetor Cold enrichment or choke system Check linkage for proper operation
not functioning. and adjustment;clean, service or
Starts Normally replace as required.
But Won't Run
Incorrect choke thermostat Adjust choke. If tamperproof,check
(Stalls) - Cold
adjustment, lean or rich. for correct assembly.
Cranks Normally Venturi valve sticking open, 7200 Clean and service as required.
But Slow to only.
Start-Cold
Accelerator pump not functioning, Visually check for fuel discharge
check visuallyfor fuel discharge. and serviceas required.
Backfire
(Induction or Leaking intake manifold or Replace leaking gaskets.
Exhaust) carburetor gaskets.
Feedback motor inoperative, 7200 Clean and service as required.
only. Refer to Section 3.
CFI/EFI ISC inoperative. Go to EEC-IV Diagnostics.
CFI/EFI - Refer to Section 11 for
Testing/Cleaning procedure in this
Section.
Throttle body, ISC-BPA Clean throttle body and ISC-BPA.
contaminated, icing. Refer to Air Throttle Body and Idle
Air Bypass Valve cleaning
procedure in this Section. For
additional information, refer to
Fuel/Engine Shop Manual Group.
out. Section:

ALL RIGHTS RESERVED
Carburetors, Throttle Bodies and Injectors 47

Rough Idle- Carburetor Cold enrichment or choke system Check linkage for proper operation
Cold not functioning. and adjustment; clean, service, or
replace as required. Check choke
Emission Test pull down adjustment. Check
Failure voltage to choke cap.
Improper idle adjustment. Perform idle adjustments.
Improper fast idle adjustments. Perform fast idle adjustments.
V~nturi valve sticking open, 7200 Clean and service as required.
only.
Venturi valve diaphragm leaking, Check and service as required.
7200 only.
Feedback motor inoperative, 7200 Check and service as required.
~nly. Refer to Group Fuel/Engine.
Metering rod bent, 7200 only. Check and service as required.
Refer to Fuel/Engine Shop Manual
Group.
Air cleaner duct vacuum motor Service or replace as required.
damaged, open to cold air source Refer to Section 3.
always.
Improper idle mixture. Perform propane check, adjust if
out of specification.
CFI/EFI Plugged, leaking or inoperative CFI only - Check for fuel
Throttle body, ISCo- BPA CFI/EFI - Refer to Section 11 for
contaminated, icing. Electric Fuel Delivery Systems.
Section.
Refer to Throttle Body and Idle Air
Bypass Valve cleaning procedure
in this Section.

ALL RIGHTS RESERVED

Stall, Stumble, Carburetor Cold enrichment or choke system Check linkage for proper operation
Hesitation - Cold not functioning. and adjustment; clean, service or
replace as required. Check choke
Hesitates or pulldown. Check voltage to choke
Stalls on cap.
Acceleration
Backfire Accelerator pump not functioning, Visually check for fuel discharge
(Induction or check visually for fuel discharge. and service as required.
Exhaust)
Low fuel pump delivery. Test fuel pump, service or replace
as required. Refer to Fuel/Engine
Shop Manual Group or Section 11.
Feedback motor malfunction, 7200 Check and service as required.
Clogged fuel filter. Clean or replace as required. Find
cause.
Power valve stuck closed. Replace power valve.
Improper or obstructed main jets. Check, clean, or replace as
required. For 7200, replace
carburetor.
Air cleaner duct vacuum motor Service or replace as required.
damaged open to cold air source. Refer to Section 3.
Venturi Valve Diaphragm failure, Replace diaphragm.
7200 only.
CFI-EFI TP sensor failure. Go to EEC-IV Diagnostics.
injectors. discharge at the injector.
CFI/EFI- Refer to Section 11 for
Section.
contaminated or icing. Refer to Throttle Body and Idle Air
Valve Bypass cleaning procedure
in this Section. For additional
information, refer to Fuel/Engine
Shop Manual Group.
out. Section.
Return to Routine 202 or 207,
Section 2.

ALL RIGHTS RESERVED

No Start - Hot Carburetor No fuel in carburetor bowl. Check by actuating accelerator
pump. If no fuel discharge is seen,
Cranks Normally check fuel delivery system. Refer
But Won't to Fuel/Engine Shop Manual
Start -,. Hot Group or Section 11.
Cold enrichment or choke system Check linkage for proper operation
not functioning. and adjustment; clean, service, or
Venturi valve sticking, 7200 only. Clean and service as required.
Flooding or loading. Check float level, adjust as
.
, required.
CFIEFI Inoperative ISC motor. Go to EEC-IV Diagnostics.
TP sensor stuck at WOT.
., Plugged, leaking, or inoperative CFI only - Check for fuel
injector. discharge while cranking engine.
Insufficient. fuel pressure. CFI/EFI- Refer to Section 11 for
Section.
Return to Routine 201, section 2.

ALL RIGHTS RESERVED
CFI, EFI & Carburetor System Diagnosis. By Symptom

Hard Start, Hot Carburetor Cold enrichment or choke system Check linkage for proper operation
Starts Normally replace as required.
But Won't Run
Incorrect choke, thermostat Adjust thermostat housing and
(Stalls) - Hot
adjustment, lean or rich. choke cap. If tamperproof,check for
correct assembly.
Cranks Normally
But Slow to Start Venturi valve sticking open, 7200 Clean and service as required.
Hot only.
Bowl vents plugged. Check internal vent for adjustment
Backfire and external ventfor kinked hose.
(Induction or
Exhaust) Feedback motor inoperative, 7200 Check and service as required.
Flooding or loading. Check float level, service as
required.
Leaking intake manifold or Replace leaking gaskets.
carburetor gaskets.
CFI/EFI Excessive fuel pressure. Clean, service or replace:
- Fuel return line.
- Fuel pressure regulator. Refer
to Section 11.
Contaminated fuel pressure Clean, service or replace fuel
regulator valve and seat. pressure regulator.
Check fuel pressure bleed down
after engine has been turned off.
Injector O-ring seal leaking. CFI / EFI - Refer to Section 11 for
Section.
ISC inoperative. Go to EEC-IV Diagnostics.

ALL RIGHTS RESERVED

Rough Idle - Hot Carburetor Cold enrichment or choke system Check linkage for proper operation
Emission Test replace as required.
Failure
Venturi valve sticking, 7200 only. Clean and service as required.
-.. Improper idle adjustments. . Perform all idle adjustments.
Throttle plates sticking. Check and service as required.
Choke pulldown diaphr~gm not Check and service as required.
functioning.
7200 only.
Improper idle mixture. Perform propane check, adjust if
out of specification.
- .
Clogged air bleeds or air Clean with solvent and compressed
passages. air.
Improper fuel level. Adjust float level.
Feedback motor, 7200 only. Check for smooth operation. Refer
to Section 3.
CFI/EFI Plugged, leaking or inoperative CFI only - Check for fuel
injector. . discharge at the injector.
Injector O-ring seal leaking. CFI/EFI- Refer to Section 11 for
Electric' Fuel Delivery Systems.
Section.
contaminated. Refer to Throttle Body and Idle Air
Bypass Valve cleaning procedures
Shop Manual Group.

ALL RIGHTS RESERVED

Stall, Stumble, Carburetor Cold enrichment or choke system Check linkage for proper operation
Hesitation - Hot not functioning. and adjustment; clean, service, or
Hesitates or Inoperative accelerator pump. Visually check for pump shot or
Stalls on a fuel siphoning. Service as requ.ired.
Acceleration-Hot
low fuel pump volume. Test pump; fuel delivery system.
Refer to Group 24 or Section 11.
Feedback motor malfunctioning, Check and service as required.
7200 only. Refer to Section 3.
Bowl vents plugged. Check internal vent adjustments,
external for kinked hoses.
Clogged fuel filter. Check and replace as required.
Check cause.
Power valve stuck closed. Replace valve.
Improper or obstructed main jets. Check, clean or replace as
required. For 7200, replace
carburetor.
7200 only.
Carburetor Feedback System Refer to appropriate MCU or EEC
Malfunction. Diagnostic procedure.
CFI/EFI TP Sensor Malfunction. Go to to EEC-IV Diagnostics.
CFIIEFI - Refer to Section 11 for
Section.
contaminated. Refer to Throttle Body and Idle Air
Bypass Valve cleaning procedure
Shop Manual Group.
Return to Routine 202 or 207,
Section 2.

ALL RIGHTS RESERVED

Low Idle Speed, Carburetor Idle speed adjustment. Check and adjust as required.
Stalls on Decel
or Quick Stop
Throttle positioner/ Dashpot not Check and service as required.
functioning.
Venturi valve sticking, 7200 only. Check and service as required.
Feedback motor malfunctioning, Check and service as required.
7200 only. Refer to Section 3.
Clogged air bleeds or idle Remove and clean with solvent
passages. and compressed air.
Venturi Valve diaphragm leaks, Replace diaphragm.
7200 only.
Leaking intake manifold or Replace leaking gaskets.
carburetor gaskets.
CFI/EFI ISC inoperative. Go to EEC-IV Diagnostics.
TP Sensor malfunction.
Base idle adjustment. Go to adjustment procedure.

ALL RIGHTS RESERVED
4-14 Carburetors, Throttle Bodies and .Injectors

Lack of Power Carburetor ~ Sticking venturi valve or leaking Check, clean and service as
diaphragm, 7200 only. required.
Misses Under
Load
Venturi valve limiter out of Adjust as required.
adjustment, 7200 only.
Accelerator pump not functioning Check and service as required.
or improper adjustment. Check
visually for fuel discharge.
Control vacuum regulator off Check and adjust as required.
specification (high), 7200 only.
Plugged pump discharge nozzle. Clean nozzle with compressed air.
Leaking fuel at pump discharge Replace gasket.
nozzle screw gasket.
Improper float setting. Adjust float level.
Main metering system plugged, Clean fuel system as required.
contaminated fuel.
7200 only.
Feedback motor, 7200 only. Check for smooth operation. Refer
to Section 3.
Fuel filter or fuel delivery lines Check fuel delivery. Refer to
restricted. Section 11. For further information,
refer to Fuel/Engine Shop Manual
Group.
Carburetor feedback system Refer to appropriate MCU or EEC
malfunction. Diagnostic procedure.
Secondary throttle plates stuck Check and service as required.
closed. Refer to Fuel/Engine Shop Manual
Group.
CFI/EFI TP sensor malfunction Go to EEC-IV Diagnostics.
injectors. discharge at the injector.
Fuel pressure regulator failure. CFI/EFI- Refer to Section 11 for
Section.

ALL RIGHTS RESERVED

Poor Mileage Carburetor Feedback motor malfunction, 7200 Check and service as required.
Misses Under
Load
Carburetor feedback system Refer to appropriate MCU
malfunction. Diagnostic Procedure.
Cold enrichment, or choke system Check choke system function and
- malfunctioning. adjustment.
Purge vent control valve Check evaporative control valve
malfunctioning. , and evaporative system. Refer to
Section 7.
CFI/EFI Injector O-ring seal leaking Perform injector leakage test.
Return to Routines 213, 219,
Section 2.

ALL RIGHTS RESERVED

Reduced Top Carburetor Venturi valve sticking, 7200 only. Check, clean and service as
Speed/Power required.
Misses Under Incorrect venturi WOT opening, Adjust as required.
Load 7200 only.
Lack of Power Binding throttle linkage. Clean and service as required.
7200 only;
Low fuel pump volume. Test fuel delivery system. Refer to
Section 11 or Fuel/Engine Shop
Manual Group.
Metering rods bent, 7200 only. Service as required.
Incorrect float drop. Adjust as required.
Clogged fuel filter. Replace as required. Check. cause.
Power valve stuck closed. Replace power valve.
Improper or obstructed main jets. Clean or replace as required. For
7200, replace carburetor.
Inoperative secondary system on Check shaft and plate alignment,
two-staged carburetors. binding linkage, service as required.
Feedback motor inoperative. Check for smooth operation. Refer
to Section 3.
Carburetor feedback system Refer to appropriate MCU
malfunction. Diagnostic procedure.
CFI/EFI Plugged, leaking, or inoperative CFI only - Check for fuel
injectors. discharge at injector.
Fuel pressure failure. CFI/EFI- Refer to Section 11 for
Section.
TP Sensor malfunction. Go to EEC-IV Diagnostics.

ALL RIGHTS RESERVED

Surge at Cruise Carburetor Restricted fuel deliv~ry or fuel Replace filter. Refer to Section 11.
filter. ,
Surges at Steady
Speed.
; Improper fuel level. Adjust float level and drop, check
float hinge pin for binding; service
"
and adjust as required.
~
Low fuel pump volume or Test fuel delivery system. Refer to

pressure. Section 11 or Fuel/Engine Shop
, .. Manual Group.
Contaminated fuel. Drain fuel, clean as required.
Damaged metering rods, 7200 Replace.
only.
Feedback motor inoperative. Check for smooth operation. Refer
to Section 3.
Blocked air bleeds. Clean and service as required.
. - Fuel-leaks around carburetor. Service as required.
CFI/EFI . Plugged or leaking fuel injectors. CFI only - Check for fuel
discharge at the injector.
CFI/EFI - Refer to Section 11 for
Section.

Flooding, Black Carburetor Float problem. Service as required. Refer to
Exhaust Smoke Fuel/Engine Shop Manual Group.
Gas Smell Damaged fuel inlet or sticking Service as required.
needle.
Emission Test
Failure
Excessive fuel pressure. Check fuel pressure.
Service fuel return line. Refer to
Section 11.
CFi/EFI Excessive fuel pressure. CFI only - Check for fuel
discharge at the injector.
Injector stuck open, or O-ring seal CFI/EFI- Refer to Section 11 for
leaking. Electric Fuel Delivery Systems.
Section.

ALL RIGHTS RESERVED

High Idle Speed Carburetor Not coming off fast idle cam. Check linkage for proper operation
Engine Diesels or and adjustment; clean, service, or
Idles too Fast replace as required.
Carburetor Incorrect idle base adjustment. Perform all idle adjustments. Go to
CFI/EFI- adjustment procedures in this
Section.
Vacuum leaks. Check all vacuum lines and
connections.
Throttle plate, ISC-BPA or linkage Visual check for proper operation.
sticking.
Clean Throttle Body and ISC-BPA.
Refer to Air Throttle Body and Idle
Air Bypass Valve cleaning
procedure in this Section. For
additional information, refer to
Fuel/Engine Shop Manual Group.

ALL RIGHTS RESERVED
Carburetors, Throttle Bodies' and Injectors 419
Throttle Body and Idle Air Bypass Valve Assembly

Cleaning Procedure Using Idle Air Bypass Actuator,
Rotunda 113-00009 or Equivalent
1. Remove air duct to Throttle Body In.let. Disconnect Bypass Valve Signal Lead and attach
actuator (Idle Air Bypass Valve Oscillator) harness plug.
2. Start actuator and engine (For vehicles with airflow meters, do not start engine at this
time). Spray Carburetor Tune-up Cleaner D9AZ-19579-AA or equivalent, into throttle bore
just enough to wet bore, Throttle Plate, and Idle Air Bypass Valve. Cycle oscillator to
make sure IABP Valve is open to accept cleaning fluid.
3. Stop engine (where applicable) and actuator and let soak for 15 minutes.
4. At end of 15 minutes, saturate cleaning brush with solvent and articulate brush between
bore and plate while holding throttle at wide open; exert some pressure against bore wall
and plate surface. Repeat saturating brush and scrubbing for two to three minutes making
sure to reach into corners near the throttle shaft ends.
5. 'Start actuator and engine. Spray Carburetor Tune-up Cleaner into throttle bore to wash
away residue (For vehicles with airflow meters, do not start engine at this time and do not
spray for longer than six seconds' continuous.) On assemblies with attached Bypass Valve,
spray cleaner into passage leading to the inlet of the valve while operating oscillator to
insure that c.leaning fluid reaches the pintle. Before proceeding with next step, insure that
throttle closes properly.
6. ~eplace air' duct. If vehicle is not to be driven within a few minutes, run engine at idle for
one minute to dry out solvent residue. Operate oscillator at this time to insure solvent flow
thru the by-pass valve.
7. Disconnect actuator from IABP Valve and reattach control signal lead.
NOTE: Use wire stem horse hair or nylon bottle cleaner type brush 1 to 1 1/2
inches thick.
Use rubber gloves and eye protection.
Vehicles with air . flow meters cannot be run with air duct removed.

ALL RIGHTS RESERVED
For 3.0L Probe, all 4.9L and S.8L (U/8S00 GVW) E and F-Series:
INote I
The curb idle and fast idle RPM are controlled by the EEC-IV processor and the idle
rpm control device and cannot be adjusted.
IRemember I
A change in idle rpm occurred because of a problem elsewhere. You should only enter this
procedure after you have eliminated the possible causes listed below: .
Contamination within the throttle bore.
Contamination within the idle speed control device.
Contaminated or defected EGO/HEGO sensor.
Throttle sticking or binding.
Engine not reaching operating temperature.
Ignition timing out of specification.
Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake
booster where applicable, etc.).
IVerify I
Transmission in PARK or NEUTRAL.
Parking brakes applied (automatic brake release disconnected where applicable).
Wheels blocked.
Cooling system filled.
Engine at operating temperature.
Heater and accessories off.
Throttle lever is resting on the throttle plate stop screw.
Ignition timing set to specification.
All engine malfunctions have been resolved.

ALL RIGHTS RESERVED
IProcedure I
1. Activate Engine Running Self-Test.
2. After service code 11 has been displayed, qUickly (within 4 seconds) 4niatch and latch the
STI button.
3. A single pulse code indicates the entry mode, then observe Self-Test Output (STO) of the
STAR tester for:
Constant tone, solid Light, or "STO LO" readout means base idle rpm is within range.
To exit test unlatch STI button, then' wait 4 seconds for reinitialization. (After 10 minutes
it will exit by itself.)
Beeping tone, flashing light, or "STO LO" readout at (8 Hz) indicates TP sensor out of
range due to over adjustment, adjustment may be required.
Beeping tone, flashing light, or "STO LO" readout at (4 Hz) indicates base idle rpm is
too fast, adjustment is required.
Beeping tone, flashing light, or "STO LO" readout at (1 Hz) indicates base idle rpm is
too slow, adjustment is required.
"
4. If adjustment is required refer to possible causes listed above and correct them as
required, then continue with Step 5.
5. Refer to figure 4, turn throttle plate stop screw until beeping tone, flashing light or "STO
LO" readout is constant.
6. Open throttle to 1500 rpm for 10 seconds, then recheck base idle rpm.

ALL RIGHTS RESERVED
Idle Speed Setting Procedures
FOR ALL OTHER CFIIEFI SYSTEMS:
INote I
The curb idle and fast idle speeds are controlled by the EECIV processor and the idle
speed control device and cannot be adjusted.
IRemember I
A change in idle speed occurred because of a problem elsewhere. .you should only enter this
procedure after. you have eliminated the possible causes listed below:
Contamination within the throttle bore.
Contamination within the idle speed control device.
Contaminated or defective EGO/HEGO sensor.
Throttle sticking or binding.
Engine not reaching operating temperature.
Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake
booster where applicable, etc.). .
IVerify I
Transmission in PARK or NEUTRAL.
Parking brakes applied (automatic brake release disconnected where applicable).
Wheels blocked.
Cooling system filled.
Engine at operating temperature.
Heater and accessories off.
Throttle lever is resting on the throttle plate stop screw (EFI only).
Ignition timing set to specification.
a. Perform EEC-IV diagnostics and resolve any vehicle malfunction that are indicated by
service output codes. (Ignore this step if you were sent here from an EEC-IV Pinpoint Test
Step).
b. Engine off, disconnect the negative (-) terminal of the battery for five minutes minimum then
reconnect it.
c. Start engine and stabilize for two minutes, then goose engine and let it return to idle, lightly
depress and release the accelerator and let engine idle. Does engine idle properly?
NOTE: If electric cooling fan comes on, wait until it turns off.
d. If engine does not idle properly, SHUT ENGINE OFF. Go to the appropriate adjustment
procedure page. Follow the procedure from top of the page in sequence to the bottom of
the page.

ALL RIGHTS RESERVED
FOR CFI ENGINES:

1. Engine off, remove air cleaner. Connect jumper wire between Self-Test Input (STI) and
Signal Return Pin on the Self Test connector (Figure 5).
2. Turn ignition key on but do not start engine. ISC plunger will retract within 10-15 seconds.
If ISC plunger does not retract, perform EEC-IV diagnostics.
3. Disconnect vehicle harness from the ISC motor. Turn ignition key off and remove jumper
wire.
4. Start engine, check idle rpm. If it is not:
1.9L: 600 + 50 rpm continue with Step 9.
2.5L: ATX 50 rpm less than specified on Decal continue with Steps 5, 6, 7 and 8.
2.5L: MTX 100 rpm less than specified on Decal continue with Steps 5, 6, 7 and 8.
5. Turn ignition key off. Remove CFI assembly from vehicle.
6. Remove the plug that covers the throttle stop adjusting screw (Figure 7).
7. Remove the old throttle stop adjusting screw and install a new screw.
8. Install the CFI assembly. Start engine and let it stabilize.
9. Adjust throttle stop adjusting screw (Figure 6 or 7). Refer to Step 4 for idle rpm.
10. Shut engine off and reconnect vehicle harness to the ISC motor. Reinstall air cleaner.

ALL RIGHTS RESERVED
ADJUSTMENT PROCEDURE 1.9L 2.3L 2.3L 2.9L 3.0L 3.0L 3.8L 3.8L 3.8L 5.0L
FOR PASSENGER CAR EFI EFI EFI EFI EFI SEFI SEFI SEFI SEFI SEFI
MAl
HO HSC OHC TURBO AXOD MA RWD AXOD
SC
REFER TO FIGURE- 4 4 4 8 4 9 4 4 4 4
1. Unplug spout line and verify that ignition timing
X X X
is Base 2 degrees BTDC (Refer to dec~I).
Remove PCV hose from intake manifold and plug
it. Remove CANP hose from intake manifold and
2. X
connect Rotunda tool :# T89P-9600-AH between
PCV andCANP ports.
3. Remove PCV hose at the PCV valve and install
X X
.200 inch diameter orifice (Tool T86P-9600-A).
4. Disconnect Idle Speed Control-Air Bypass
X X X X X X
Solenoid.
5. Start engine and run at: rpm/sec ....................... 2000/60 2500/30 1500/30 2000/120 2000/30 IDLE
6. Place automatic transmission in ......................... Park Drive Park Park Drive Park Park Park Park
manual transmission in Neutral Neutral
7. Engine off, back out throttle plate stop screw X
X X X
clear off the. throttle lever pad.
8. With a .010 in. feeler gauge between the throttle
1.2
plate stop screw and the throttle lever pad turn
the screw in until contact is made then turn
it an additional ............................................... 1.5 1.5 1.5
turns turns turns
9. Check1adjust idle rpm:
Loosen the throttle camplate roller bolt ........... X
Turn the throttle plate stop screw to (rpm) ...... 95050 A 102550 A 65025
M 155050 M 60025
7oo25 76020 8oo30
Tiqhten the throttle camplate roller bolt ........... X

See NOTE below. Shut engine off and repeat
steps 5, 6, 9.................................................. X X
10. Shut engine off and disconnect battery for 5
minutes minimum. X X X
11. Engine off reconnect spout line. X X X
12. Remove Rotunda tool. Unplug PCV hose. X
Reconnect CANP and PCV hoses to the intake
manifold. X
13. Remove orifice from PCV hose and reconnect to
PCV valve. X X
14. Engine off reconnect idle speed control-air bypass
solenoid verify the throttle is not stuck in the bore X X X X X X
and linkage not preventing throttle from closing.
15. Start engine and stabilize for 2 minutes then
goose engine and let it return to idle, lightly
depress and release the accelerator. Let engine X X X X X X X X X X
idle .............................................................. II Idle problem stili exists, Go To Section 2 for other possible causes.
16. On Automatic Overdrive Transmission (AOD)
applications or Automatic Transaxle (AXOD) X X X X
application check TV adjustment.
NOTE For Step 9: After a time, Idle speed may change due to strategy parameter.
1 1 1/2 turns 5.0L HI Output Engine
2 1 7/8 turns 5.0L base Engine
65050 1.9L SEFI MA (CT20)

ALL RIGHTS RESERVED
ADJUSTMENT PROCEDURE 2.3l 2.9l 3.0l 4.0l 5.0l 5.8l 7.5l

EFI
FOR TRUCK EFI EFI EFI EFI EFI EFI
0/8500 GVW
OHC
REFER TO FIGURE- 4 4 4 4 4 4 4
1. With engine off install specified feeler A .050 in. A .030 in.
gauge between throttle plate stop screw M .030 in. M .030 in.
and throttle lever.
2. Unplug spout line and verify that ignition X X X
timing is base 2 degrees BTDC (Refer to
decal).
3. Disconnect idle speed control-air bypass
solenoid.
X X X X X X X
4. With transmission in Neutral or Park: .......... X X X X X X X

Run enQine at: rom/sec .................. :...... 2500/30 2500/30 2500/30 2500/30 2500/30
Let engine idle for 2 minutes X X
5. Place automatic transmission in ................ Park Park Drive Park Park Park Park
manual transmission in Neutral.
6. Check/adjust idle rpm: A 62525 A 675+50 C6 780+50 C6650+50
Turn the throttle plate stop screw
to (rpm) ................................................ 57525 725 25 M 72525 675 M 700+50 E40D E40D
730+50 650+50
MAN MAN
730+50 650+25
See Note Below
7. Shut engine off and repeat Steps 4, 5,
X X X
and 6.
8. Shut engine off and disconnect battery for
X X X X
5 minutes minimum.
9. Remove feeler gauge from throttle plate
X X
stop screw and throttle lever pad.
10. Reconnect spout line. X X X
11. Engine off reconnect idle speed control-air
bypass solenoid, verify the throttle is not
X X X X X X X
stuck in the bore and linkage not
preventing throttle from closing.
12. Start engine and stabilize for 2 minutes X X A 72050 X X X X
then goose engine and let it return -to idle, M 80050
lightly depress and release the accelerator. See Note Below
Let engine idle ............................ :.......... If idle problem still exists, Go To Section 2 for other possible causes.
13. On Automatic Overdrive Transmission (AOD)
X
applications check TV pressure adjustment.
NOTE: For Step 6, if you must tum the throttle stop screw in, shut engine off, make estimated adjustment. Start
engine and repeat Steps 4, 5, and 6 before continuing.
NOTE: For Step 12, a condition may occur where the engine rpm will oscillate. This can be caused by the throttle
plates being open enough to allow purge flow. To verify this condition, disconnect the carbon canister purge
line and plug It. If purge Is present, the throttle plates must be closed until the purge flow Induced Idle
oscillations stop.

ALL RIGHTS RESERVED
THROTTLE STOP
ADJUSTING SCREW
SIGNAL RETURN .....,
---STI---------- TO SELFTEST
INPUT (STI)
A778tC
IDLE SPEED
CONTROL (ISC)
HARNESS
CONNECTOR
A9865-8
Figure 5 1.9L CFI and 2.5L CFI HSC Figure 6 1.9L CFI
IDLE SPEED CONTROL

(ISC) CONNECTOR ----_~~
A8318-C
Figure 7 2.5L CFI HSC

ALL RIGHTS RESERVED
THROTTLE CAMPLATE
( ~OlLER(BOL~
"J ~
~~, / A11402-A
Figure 8 2.9L EFI
Figure 9 3.0L SEFI MA

ALL RIGHTS RESERVED
5.al (W) ENGINE W/7200-VV - PASSENGER CAR
Fast Idle RPM
Instructions
1. Place the transmission in NEUTRAL or PARK. Set parking brake and block wheels. If
equipped with automatic brake release, disconnect vacuum hose and plug it.
2. Bring engine to normal operating temperature.
3. Place A/C-Heat Selector to the OFF position.
4. Disconnect the vacuum hose at the EGR valve and plug.
5. Place the fast idle adjustment on the second step of the fast idle cam (Figure 10).
Checkladjust fast idle rpm to specification.
6. Rev engine momentarily, place fast idle adjustment on the specified step and recheck fast
idle rpm.
7. Remove plug from EGR vacuum hose and reconnect.

ALL RIGHTS RESERVED
S.8l (W) ENGINE W/7200-YY - PASSENGER CAR
Curb Idle RPM
Instructions
equipped with automatic brake release, disconnect ,the vacuum hose and plug it.
2. Bring the engine to normal operating temperature.
3. Place Ale-Heat selector to the OFF position.
4. Disconnect and plug the vacuum hose at the throttle kicker.
5. Place the transmission in specified position.
6. Check curb idle rpm. If adjustment is required, adjust the curb idle speed screw (Fig'ure 11).
7. Place the transmission in NEUTRAL or PARK. Rev the engine momentarily. Place the
transmission in specified position and recheck curb idle rpm and readjust only if required.
8. Apply a slight pressure on top of the nylon nut located on the accelerator pump to take
up the linkage clearance.
9. Turn the nylon nut on the accelerator pump rod clockwise until a .010 .005 clearance
is obtained between the top of the accelerator pump and the pump lever.
10. Turn the accelerator pump rod one turn counterclockwise to set the lever lash preload.
11. Remove the plug from the throttle kicker vacuum hose and reconnect.

ALL RIGHTS RESERVED
S.8L (W) ENGINE W/7200-VV - PASSENGER CAR
Kicker Speed Set
Instructions
equipped with automatic brake release, disconnect the vacuum hose and plug it.
2. Bring engine to normal operating temperature.
3. Place the A/C-Heat selector in the OFF position.
4. Disconnect and plug the vacuum hose at the VOTM kicker.
5. Connect an external vacuum source providing a minimum of 33.7 kPa (10 in-Hg) to the
VOTM kicker.
6. Place the transmission selector in the specified position.
7. Check VOTM kicker speed. If adjustment is required, loosen the saddle bracket hold-down
screw, then turn the VOTM kicker speed adjusting screw. After adjustment is made,
tighten the saddle bracket hold-down screw (Figure 11).
8. ~emove external vacuum source. Remove plug from VOTM kicker hose and reconnect.

ALL RIGHTS RESERVED
Carburetors, Throttle Bodies and- Injectors 431
FAST IDLE
ADJUSTING SCREW
A6242-<:
Figure 10 5.8L w/7200-VV Carburetor- Fast Idle RPM Adjus!ment
CURB IDLE
SPEED SCREW
A6248-F
Figure 11 5.8L w/7200-VV Carburetor and VOTM (Kicker) Dashpot

ALL RIGHTS RESERVED
6.1L & 7.0L ENGINES-TRUCK, OVER 8500 GVW
Fast Idle RPM
6.1L 7.OL
2380EG2V 4190EG4V
Instructions
1. Stabilize engine temperature. X X
2. Place the vehicle in PARK or NEUTRAL, A/C

in OFF position, and set parking brake. X X
3. Remove air cleaner. X X
4. Disconnect and plug evaporative emission purge

valve hose. X X
5. Disconnect and plug EGR valve vacuum hose. X X
6. Bypass vacuum retard delay valve in distributor

advance line with vacuum hose. X X
7. Depress accelerator pedal fully, pull choke

control to full choke and release accelerator
pedal. X X
8. Check/adjust choke plate pulldown clearance.

a. Move the choke operating lever to the first
detent, Figure 12 16
b. Measure the choke plate pulldown clearance
using a size .200 in .234 in
drill. Place the drill between the air horn wall
and lower edge of the choke plate.
c. Adjust the clearance if necessary by bending
the choke link, Figure 12 14
9. Check/adjust fast idle rpm. Insert a 0.375-inch

gauge between choke plate and air horn in the
down~stream side of the choke plate. Adjust
fast idle rpm by turning fast idle adjusting
screw, Figure 12 15
10. Remove the plug from the EGR vacuum hose

and reconnect. X X
11. Remove bypass hose and reinstall the vacuum

retard delay valve. X X
12~ Remove the plug from the evaporative emission

purge valve hose and reconnect. X X
13. Reinstall air cleaner. X X

ALL RIGHTS RESERVED
6.1L & 7.0L ENGINES-TRUCK, OVER 8500 GVW
Curb Idle Speed Decel Throttle Control Speed and Anti-Dieseling Set Speed
6.1L 7.0L
2380EG2V 4190EG-4V
Instructions
1. Stabilize engine temperature. X X
2. Place the transmission in PARK or NEUTRAL,

Ale in OFF position and set parking brake. X X
3. Disconnect shed system hose and hot and cold

air supply from air cleaner. X X
4. Remove air cleaner. X X
Adjust curb idle, if necessary, using the curb

idle adjusting screw with transmission in .
5. NEUTRAL. Refer to Figure 12 13
6. Rev the engine momentarily, recheck curb idle'
and adjust if necessary. X X
With sOlo-pot collapsed (de-energized), set the

anti-dieseling speed if necessary by adjusting
7. the screw until specified rpm is attained. Refer
to Figure 12 13
8. Reinstall the air cleaner. X X
9. Reinstall shed system hose and hot and cold

air supply systems. X X

ALL RIGHTS RESERVED
ANTt-DIESELlNG~~;:;;~~~~~~
SPEED SCREW
A8534C
Figure 12 6. 1L Engine with 2380 EG 2V-Curb Idle, Anti-Dieseling and Fast Idle Speed
Adjustments
ANTI-DlESELlNG---::::=::e1~::1:~~~-A
SPEED SCREW
CURB IDLE
ADJUSTING SCREW
A8535-8
Figure 13 7.0L Engine with 4190 EG-4V-Curb Idle and Anti-Dieseling Adjustments

ALL RIGHTS RESERVED

[
CHOKE LINK
BENT TO
ADJUST
PULLDOWN
A9870C
Figure 14 7.0L Engines with 4190 EG-4V - Choke Plate Pulldown Clearance Adjustment
FAST IDLE
ADJUSTING SCREW
Figure 15 7.0L Engines with 4190 EG-4V-Fast Idle Speed Adjustment

ALL RIGHTS RESERVED
CHOKE
OPERATING
LEVER
A9869B
Figure 16 7.0L Engines with 4190 EG-4V - Fast Idle Speed Adjustment

ALL RIGHTS RESERVED
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE - PROPANE ENRICHMENT METHOD

NOTE: This procedure Is for 6.1 Land 7.0L 0/8500 GVW Truck gasoline engines with
Holley carburetors Model 2380 EG 2V and Model 4190 EG 4V for 1985-1989. If
CO and He are not within specification, go to Diagnostic Routines in Section 2.
Also refer to Maintenance Schedule.
1. Start engine and bring to operating' temperature' with vehicle in NEUTRAL, parking brake
on and air cleaner removed.
2. Set ign~tion timing to specification (Refer to decal).
3. Connect an analog tachometer, Rotunda 059-0001, or an equivalent, tachometer.
4. Disconnect the 'fuel evaporative purge hose 'from the top of the "F" fitting on the top of
the PCV valve. Connect propane enrichment tool Rotunda T75L-9600-A or an equivalent to
the top of the PCV F-fitting. Remove the PCV valve from the grommet and vent to
atmosphere keeping valve in vertical position. Allow the crankcase vent hose (from the air
cleaner top) to vent to underhood air during idle fuel mixture check.
5. Run the engine at 2500 rpm for approximately 15 seconds before each mixture check.
6. Check the engine idle speed, if necessary, set to 800 rpm.
7. With the propane tank in the vertical position, gradually open the propane tool valve and
watch for engine speed gain, if any, on the tachometer. When the engine speed reaches
a maximum and then begins to drop off, note the amount of speed gain.
8. The specified speed gain is 100-115 rpm. Compare measured speed gain to specified
gain. If the. measured speed gain is not between 100 to 115 rpm, remove the carburetor
and access the idle mixture screws by removing the tamper resistant concealment plugs
(see Fuel Group) in the Medium/Heavy Truck Shop Manual, for procedure). When
reinstalling the carburetor, be sure to replace both the carburetor to spacer and spacer to
manifold gas~ets.
9. Re.check the measured speed gain.
If the measured speed gain is higher than the speed gain specification, turn the mixture
screws counter-clockwise (out) in equal amounts repeating Steps 5 and 7 until the
measure speed gain is in the range of 100-115 rpm.
If the measured speed gain is lower than the speed gain specification, turn the mixture
screws clockwise in equal amounts repeating Steps 5 and 7 until the measured speed
gain is in the range of 100-115 rpm.
10. When the measured speed gain is within the 100-115 rpm range, turn off engine.
11. Reinstall the tamper resistant concealment plugs.
12. Install the PCV valve in the grommet. Remove the Rotunda tool or an equivalent, from
the top of the F-fitting. Reinstall the evaporative purge hose at the top of the F-fitting.
Reinstall the air cleaner.
13. Restart engine and run at 2500 rpm for 15 seconds. Set curb idle speed on energized
solenoid to 850-875 rpm.
14. Turn engine off and remove all test equipment.

ALL RIGHTS RESERVED
Cold Enrichment System
S.8l (W) ENGINE W/7200-VV - PASSENGER CAR

Cold Enrichment System - Motorcraft 7200-VV
I. Pre-Check Instructions
A. Apply parking brake and block the wheels.
B. Remove the air cleaner assembly and plug the vacuum hose(s) leading to the air
cleaner.
1. With the choke cap cool to the touch, turn the ignition key to the RUN position
without starting the engine for two minutes. The choke cap should not be warm to
the touch.
2. Start the engine if the cold enrichment rod is up when the fast idle cam is freed
from the fast idle lever. Run the engine; do not exceed three minutes. The cold
enrichment rod should seat. Turn the engine off.
C. Manually set the fast idle lever on the specified step (refer to Engine Emission Decal)
of the cam, counting the highest step as the first.
D. Start the engine and bring it to normal operating temperature.
E. Open the throttle and check to see if the cam freely falls to the full off position. If it
is functioning properly, there should be a definite drop in engine speed when the
throttle is released.
F. Turn off the engine.
II. Freedom of Linkage and System Integrity Check
A. Verify that vacuum hoses, solenoid and electric choke wires are properly connected
and intact. Check to make sure all carburetor hold-down nuts are tightened to
specification. Correct as required.
B. Check all carburetor linkages for freedom of operation. If no binding exists, proceed to
Section III. If binding exists, proceed to C.
C. Cold Enrichment Rod (CER) Mechanism Check
1. Check for damaged, foreign, missing and/or misaligned parts. Check for dirt, grease,
or any foreign material on moving parts. Service or replace as required.
If linkage is serviced or replaced, check choke adjustments. Reset if necessary.

2. Remove the retaining E-ring that holds the choke control rod to the choke shaft
lever, then disengage the linkage from the lever.
3. Open the throttle slightly and check the choke shaft lever for freedom of movement.
The choke cap and the pulldown diaphragm return spring should provide the only
resistance, and the choke shaft lever should spring back to the original position.
Clean, service or replace as required.
4. To check if the carburetor has a sticking/binding CER" perform the following
procedure.
a. Open the throttle to allow fast idle cam to move to "choke on" position.
b. Hold the choke pulldown diaphragm in its retracted position.
c. Push the CER down to its seated position. Feel for any friction/binding.

ALL RIGHTS RESERVED
d. Release the CER; it should return to its original position automatically (room
temperature or colder).
e. Observe the upward movement of the CER for any indication of sticking/binding.
f. Rotate the CER 90 degrees from its original position and repeat Steps B
through E.
NOTE: CER can be rotated using your fingers if the rod is placed in its full
up position. The number identification on top of the CER can be used for
determining the 90 degree rotation requirement.
g. Rotate the CER another 90 degrees (total of 180 degrees from its original
position) and repeat Steps B through E.
5. Verify if the carburetor has a sticking/binding Control Vacuum Regulator (CVR) with
the following procedure:
a. Hold the choke pulldown diaphragm in its retracted position.
b. Place the fast idle lever on the highest step of the fast idle cam.
c. Push the CVR down to its seated position. Feel for any friction/binding.
d. Release the CVR, 70F or warmer, the CVRshould lift-off its seat automatically,
colder than 70F, push down on the CER to lift the CVR.
e. Observe the upward movement of the CVR for any indication of sticking/binding.
6. If cam movement is still not free, remove carburetor from vehicle, then remove the
throttle body from the carburetor. Remove the choke cap, the choke shaft and lever
assembly, and the fast idle cam. Check the surfaces of all parts for grease, foreign
material, bends, cracks, or distortion. Clean or replace parts as required. If a new
fast idle cam is installed, adjust cam set according to procedure in Section V and
tighten to specification.
7. If movement is okay, make sure the choke control rod is connected to the choke
shaft lever with the retaining E-ring. If the "CVR" causes binding, replace and reset,
as outlined in Section V and Fuel Shop Manual Group.
8. Reinstall the carburetor, as outlined in Section VI.
III. Electric Chok~ Functional Test
A. Choke Circuit Test
NOTE: Refer to body wiring diagrams for detailed information on electrical
circuitry affected in this test. Two different types of circuitry are used. For
battery powered choke, the choke cap and the oil pressure switch are
connected in series through the wiring harness connectors.
For alternator powered choke, the choke cap wire is connected to the alternator
stator terminal connection.
Either type is readily identifiable by visually tracing the routing from the choke
cap terminal.

ALL RIGHTS RESERVED
To perform continuity tests of Section III Steps A-1 and -2, listed below,
disconnect the stator terminal of the alternator for alternator powered choke.
Reconnect after completion of testing.
1. Choke Cap Continuity
a. Turn ignition switch off.
b. Connect one end of a test lamp to the positive terminal of the battery and the
other end to the choke cap terminal. The test lamp should light, indicating
continuity. If it does light proceed to Step 2, if it does not, light continue with
Step C.
c. Connect one end of a jumper wire to the choke cap clamp shroud and the
other end to the negative terminal of the battery. Also connect one lead of a
test lamp to the positive terminal of the battery and the other lead to the choke
cap terminal.
d. The test lamp should light indicating continuity; if not, connect the jumper wire
directly to the choke cap ground; if the lamp lights, correct the poor contact
between the choke cap clamp shroud and the choke cap ground. If the lamp
does not light, replace the choke cap.
2. Continuity of all other circuit components, battery powered choke.
a. Turn engine and ignition switch off.
b. Disconnect oil pressure switch from harness, use a jumper wire in place of the
switch to complete the circuit.
c. COnllect one lead of a test lamp to the negative terminal of the battery and the
other lead to the choke cap terminal.
d. Turn the ignition key to the RUN position without starting the engine. The lamp
should be lit. If not, locate and service the open circuit by checking fuse, fuse
link, connector, etc.
e. Remove the jumper wire used as a substitute for the oil pressure switch;
reconnect the harness lead wire to the oil switch terminal.
f. Turn the ignition switch to the RUN position without starting the engine. The test
lamp should not indicate continuity. If the lamp indicates continuity, the oil
pressure switch is defective.
g. Start the engine. The test lamp should indicate continuity. If the lamp does not
indicate continuity, the oil pressure switch is defective.
3. Continuity of all other circuit components, alternator powered choke:
a. Connect one lead of a test lamp to the choke cap ground and the other lead to
the negative terminal of the battery.
b. Start the engine, the test lamp should indicate continuity. If not, locate and
service open circuit between choke cap to alternator stator terminal. If no open
circuit is found, check alternator output and service as required.

ALL RIGHTS RESERVED
B. Choke Control Diaphragm Check
1. Check for bending, misaligned linkage, broken parts, contamination and/or loose
parts. Service as required.
NOTE: The vacuum system used is:
a. Externally Ported Vacuum With Fuel Separator/Filter: A vacuum connector

tube is provided on the diaphragm cover, and the vacuum line runs directly from
this tube to the Fuel Separator I Filter to the manifold vacuum tap.
2. Running Engine Test
Start the engine and watch for the choke diaphragm rod to retract. If the retraction
timing is within specification listed in Special Specifications Issue TSB Publications,
the choke control diaphragm is functioning properly and no further check is
necessary.
If the timing is out of specification or there is no retraction, continue with Step 3.
3. Diaphragm Inspection, Cover Removed..
a. Remove the diaphragm cover and the diaphragm as. outlined in the Fuel Shop
Manual Group (removal of the carburetor is not necessary, but h~lpful).
b. Visually inspect the- diaphragm. If cut or torn, replace the diaphragm with a new
one and assemble it with the original cover on the carburetor and continue with
Step C.
If the diaphragm is not cut or torn, replace the cover with a new one and
assemble it 'with the original diaphragm on the carburetor and continue with Step
C. Ensure the assembly is sufficiently "tight to prevent vacuum bleed-off at
diaphragm mounting.
c. Connect a vacuum line from the connector tube on the diaphragm cover to a
powered vacuum source. Apply 60 kPa (18 in-Hg) vacuum to the diaphragm and
proceed with one of the following substeps, depending upon how the carburetor
reacts to the vacuum:
1. It -retracts the diaphragm within the specification timing. No further check is

necessary since the control diaphragm is functioning properly. Adjust any
CER setting affected by component replacement per Section IV, Step B.
2. It does not retract the diaphragm within specification or it does not retract at
all. Replace the cover with a new part, assemble* it with the existing
diaphragm onto the carburetor, and repeat this test again. Be sure the
assembly is sufficiently tight to prevent vacuum bleed-off at diaphragm
mounting.

ALL RIGHTS RESERVED
C. Choke Cap Resistance Test
1. Connect one lead of an ohmmeter to choke cap terminal and the other lead to
choke cap ground. Ensure metal-to-metal contact is achieved (not metal-oxide film-
metal) and false readings are prevented. Throughout this test, the ohm reading
should be under 30 but never zero. At any point of this test, if the ohm reading is
outside this range, start the test all over. If this same improper reading repeats, the
choke cap is defective. The cap should be replaced as outlined in the Shop Manual
Fuel Group.
2. With the choke cap connected electrically, start the engine and run for three
minutes. Shut the engine off. During this three minutes, the CER should remain
seated for an engine which was warm at the beginning. This rod should gradually
lower to seat for an engine which was cold at the beginning. If the CER does not
respond this way, note this fact and continue on with the test.
3. The choke cap should be quite warm to the touch now. Using choke tester, cool
the cap down by directing cold air toward the oval-shaped insulator (not the case)
around the cap terminal. The ohm reading should gradually vary and eventually a
sudden increase is noticeable. Stop the cooling. This sudden increase should take
place within 10 minutes since cooling began, if the Rotunda tool is employed at
maximum effectiveness and was placed as close to the cap as possible. If this
sudden resistance change does not take place within the above time limit, the choke
cap is defective and should be replaced as outlined in the Fuel Shop Manual Group.
If this sudden change takes place within this time limit, continue on with the testing.
4. Using the choke tester of Step 3 (or equivalent), warm up the cap by directing hot
air toward the oval-shaped insulator. The ohm reading should vary gradually and
eventually a sudden decrease is noticeable. Stop the warming. This sudden decrease
should take place within 10 minutes since warming began, if the tool is employed at
maximum effectiveness and was placed as close to the cap as possible.
If the sudden resistance change does not take place within the above time limit, the
choke cap is defective and should be replaced as outlined in the Fuel Shop Manual
Group.
If this sudden change takes place within the time limit, the choke cap has been
checked-out all right as far as its resistance is concerned; it generates heat in the
way it should.
5. The choke cap test itself is concluded. However, if the CER response in Step 2 is
not proper, the procedure shown in Section II should be performed to identify and
service the linkage-related problem that causes this improper response.

ALL RIGHTS RESERVED
IV. Carburetor Choke Adjustment - CER, CVR Settings
CER 24C (75F) Run, CER -18C (OF) Start and Control Vacuum Regulator
Setting
A. Cold Enrichment Rod (CER) Adju'stment Sequence
NOTE: The CER mechanism affects carburetor air/fuel mixtures throughout
engine operation, cold and warm. Several adjustments are required. Although
each adjustment does affect a particular phase of operation, and each
"maladJustment" can lead to a particular performance symptom, the adjustment
procedure must be performed completely and in the following described
sequence to provide desired CER performance.
If adjustment cannot be accomplished due to epoxy in the adjustment nut, a new
service assembly (9F685) must be installed. Refer to Step B.
1. Remove carburetor from engine.
2. Assemble Dial Indicator Kit TOOL-4201-C or equivalent, to carburetor.
NOTE: CER adjustment specifications are listed on a tag attached to the

carburetor above the choke cap (Figure 26), and published in the Special
Specifications Issue TSB Publications.
3. Remove choke diaphragm cover and spring.
4. Remove choke cap according to appropr.iate instructions.
5. Compress the idle speed positioner where applicable and insert a 5/16-1/2 inch
spacer between the positioner stem and the throttle lever contact paddle. Retain
in this position with a rubber band. This will locate the fast idle pick-up lever away
from the cam and allow the cam to rotate freely.
6. Install Stator Cap T77L-9848-A or equivalent as a weight to rotate bimetal lever
counterclockwise (CCW) and seat the CER.
7. Install dial indicator with tip centered on top surface of CER.. Set the dial indicator
to zero. Raise weight slightly and release to check for accurate zero.
NOTE: This adjustment will be the reference for other adjustments. Be sure dial
Indicator reading is accurate (Figure 18).
B. 'Control Vacuum Regulator (CVR) Swivel Assembly Replacement
Refer to Figure 3.
CVR/CER nuts have cylindrical projections above the threads which are filled with
epoxy after final adjustment. To adjust, the existing parts must be removed and a new
assembly installed. After adjusting, CVR/CER nut cavities must again be filled with
epoxy. .
1. Remove the E-clip and hinge pin.
2. Turn the CER adjusting nut counterclockwise until nut disengages from' rod.
3. Remove the CVR and swivel assembly. Replace with new assembly.
4. The unbroken rod must be' in place first before further assembly. Install the
assembly and tighten the CER adjusting nut to lower and locate into position.
Connect lever to swivel.

ALL RIGHTS RESERVED
5. Install the hinge pin and E-c1ip.
6. For CVR/CER adjustments, refer to Step 3.
7. Fill two nuts and stop screw with MT13 epoxy or equivalent.
NOTE: The rod has an undercut designed to break, if breakage does occur,
a new rod assembly must be installed. The upper body must be loosened to
position the rod through the opening. Replace the upper body gasket as
necessary (Fig. 20).
C. CER Run Position (24C, 75F) Adjustment
Refer to Figure 21.
1. Install stator cap and rotate clockwise (CW) to index. Dial should indicate the tag
specification for Run at 24C (75F) 0.010 inch.
2. Adjust by turning choke adjusting nut CW to increase or CCW to decrease height.
D. CER Start (Crank) Position (18C, OaF) Adjustment
Refer to Figure 22.
1. Remove stator cap.
2. Rotate choke bimetal lever CW until CER travel stop screw bottoms on choke
seal retainer (full travel). Dial should indicate the tag specification for Start at 18C
(OF) 0.005 inch.
3. Adjust by turning CER travel stop screw with 5/64 inch hex wrench, CW to
decrease or CCW to increase height.
E. Choke Diaphragm Start (Crank) Position for Warm Engine (24C, 75F)
Refer to Figure 23.
1. Push in diaphragm assembly. Dial should indicate the tag specification for Start at
24C (75F) 0.020 inch.
2. Adjust by rotating the diaphragm assembly CW to decrease or CCW to increase

height.
F. Control Vacuum Rod (CVR) Position

Refer to Figures 24 and 25.
1. Seat CER again using stator cap weight and check for zero dial indicator reading.
Reset zero position of indicator if required. Remove stator cap weight (Figure 24).
2. Depress the CVR until seated. Dial should indicate the tag specification for CVR
0.10 inch.
3. Adjust by holding CVR with 3/8 inch wrench, and turning adjustment with 3/32
inch hex wrench CW to decrease or CCW to increase height (Figure 25).
4. Reinstall original choke diaphragm cover with original spring.

ALL RIGHTS RESERVED
G. Choke Diaphragm Run Position for Cold Engine (- 18C, OF)

Refer to Figure 26.
1. Apply vacuum to choke diaphragm cover, or, depress choke diaphragm rod to
seated position.
2. Rotate choke bimetal lever CW until choke shaft lever pin contacts fast idle
intermediate lever. Dial should indicate the tag specification for Run at OF
0.005 inch.
3. If an adjustment is required, remove the choke diaphragm cover and install a new
cover with the original spring. This is necessary due to tamper-resistant material
on the adjustment screw.
'4. Adjust by rotating screw in diaphragm housing with 5/64 hex wrench, CW to
increase or CCW to decr~ase height.
5. Apply sealing liquid on adjustment screw to secure adjustment.
6. Install lead ball plug in adjusting screw hole.
H. Fast Idle Cam Setting
Refer to Figure 27.
Position fast idle pick-up lever on second step of fast idle cam against shoulder of
high step.
1. Install stator cap and rotate CW until fast idle pick-up lever contacts fast idle cam
adjusting screw. Dial should indicate specification 0.360 inch 0.005 inch.
2. Adjust by rotating fast idle cam adjusting screw.
3. Remove stator cap.
4. Assemble choke cap, gasket, and retainer with breakaway screws.
5. Remove dial indicator and rubber band.
6. Install carburetor and adjust idle speeds.
V. Post-Check Instructions
A. Inspect the gaskets and sealing surfaces between the carburetor and intake manifold.
Service as required.
B. Reinstall the carburetor.
C. Reconnect all wire connections and hoses.
D. Check/adjust engine idle speeds.
E. Reinstall the air cleaner assembly and reconnect pertinent vacuum lines. * Tighten air
cleaner wing ~uts to specification.
Verify that air cleaner heat riser tube and fresh air pick-up connections are correct.
VI. Removal and Installation of Adjustment Limiting Choke Bimetal Housing and
Enrichment Rods
A. Refer to Fuel/Engine Shop Manual Group.
*Refer to the Special Specifications Issue TSB Publications.

ALL RIGHTS RESERVED
COLD ENRICHMENT
SPECIFICATIONS TAG ---~!Lt:--t==-J--LJI
A7227B
Figure 17 Cold Enrichment Rod (CER) Adjustment Sequence
I
DIAL
TOR
CER RUN START

DIAPHRAGM
COVER
REMOVED
STATOR
CAP
iJ
75 000 000 E2AE
0 000 000 9C911
CVR 000 DA
A7228-B
Figure 18 CER Run Position (24C, 75F) Adjustment

ALL RIGHTS RESERVED
Carburetors, Throttle Bodies and -Injectors 4-47
CER
ADJUSTING
NUT
A7229-B
Figure 19 Control Vacuum Regulator (CVR) Swivel Assembly Replacement
OF START CER ADJUSTMENT

ADJUSTMENT NUT CAVITY
STOP SCREW FILLED WITH EPOXY
CAVITY FILLED
~WITH EPOXY
b
CER
r......,llu.....J"--- LEVER
CHOKE SHAFT ROO

CASE HARDENED
BREAKAWAY GROOVE
A723O-B
Figure 20 CERICVR Tamper Resistant Installation

ALL RIGHTS RESERVED
CHOKE
ADJUSTING
NUT
A7231B
Figure 21 CER Run Position (24C, 75F) Adjustment
CER RUN START

75 0 000 000 E2AE
()O 000 000 9C911
CVA 000 DA
5164" HEX
WRENCH
A7232-8
FigI;Jre 22 CER Start (Crank) Position (- 18C, OF) Adjustment

ALL RIGHTS RESERVED
eER RUN
75 000 eER RUN START
0 000 75 000 000 E2AE
eVR 000 0 000 000 9C911
eVR 000 DA
READ
HEIGHT
DIAPHRAGM
ASSEMBLY
eVR POSITION A7234-B

A7233-B
Figure 23 Choke Diaphragm Start (Crank) Figure 24 Control Vacuum Rod (CVR)
Position - Warm (24C, 75F) Position - Check
A7235-8
eVR POSITION
Figure 25 Control Vacuum Rod (CVR)

Adjustment

ALL RIGHTS RESERVED
4-50 Carburetors, Throttle Bodies and Inlectors
CER RUN START

75 000 000 E2AE
0 000 000 9C911
CVA 000 DA FAST IDLE CAM
ADJUSTING SCREW
CHOKE SHAFT
LEVER PIN
FAST IDLE
INTERMEDIATE
LEVER
FAST IDLE
DEPRESS PICKUP LEVER
TO SEAT
DIAPHRAGM
A7231-8
Figure 26 Choke Diaphragm Run Position for Cold Engine (- 18C, OF)
FAST IDLE CAM

ADJUSTING
SCREW A
'\-
A7237B
Figure 27 Fast Idle Cam Setting

ALL RIGHTS RESERVED
Choke Adjustment Procedure
6.1L AND 7.0L ENGINES TRUCK, OVER 8500 GVW
Manual Choke Carburetors Only - Holley 2380EG-2V and 4190EG-4V
I. Pre-Check Instructions
A. Apply parking brake, and .block wheels. Manual!Auto transmission in NEUTRAL.
B. Bring the engine to normal operating temperature.
C. Remove the air cleaner assembly.
D. Disconnect choke cable from carburetor.
E. Check all carburetor linkages for freedom of operation. Service, replace or adjust as
required.
F. Check for freedom of operation of choke plate for closing and opening in the air horn
bore. Correct as required.
G. Reconnect choke cable and check choke plate travel using dashboard control.
Depress throttle and pull choke full on. Choke should be fully closed in air horn bore.
Depress throttle and push choke in. Choke should be fully open. Correct choke cable
adjustment as required.
II. Post-Check Instructions
Reinstall the air cleaner assembly. Tighten the air cleaner wing nut to specification.
*Refer to Fuel Shop Manual Group for additional information.

ALL RIGHTS RESERVED
Fuel Injector Testing/Cleaning
DESCRIPTION
The Fuel Injector (Figure 28) is a solenoid operated valve that meters fuel flow to the engine.
The injector is opened and closed a constant number of times per crank revolution. The
amount of fuel is controlled by the length of time it is held open.
The injector is normally closed and is operated by a signal from the Electronic Engine Control
(EEC) module.
There are several Deposit Resistant Injector (DRI) designs (Figure 29).
INTEGRAL FILTER
FUEL RAIL O-RING
SEAL
COIL
PINTLE PROTECTION CAP

PINTLE
HIGH-PRESSURE EFI
A7186-C
Figure 28 High Pressure Injector

ALL RIGHTS RESERVED
Fuel Injector Testing/Cleaning
THE MAJORITY OF THE FUEL METERING FUNCTION IS

MOveD WITH THE INJECTOR AND IS HANDLED BY AN
INTERNAL UPSTREAM ORIFICE INSERTED INTO THE
ADJUSTING TUBE.
DEPOSIT RESISTANT INJECTOR (DRI)

METERING ASSEMBLY
THE REMAINING METERING OF FUEL IS STILL

ACCOMPLISHED AT THE PINTLE/SEAT ASSEMBLY -
BUT NOW ITS VARIATIONS AFFECT ONLY A FRACTION
OF THE lOTAL FUEL FLOW.
TOP FEED STAGE III
DIRECTORIMETERING PLATE TOP FEED STAGE III (TOSK II)
A12767A
Figure 29 Deposit Resistant Injector (DR/) Designs

ALL RIGHTS RESERVED
Fuel Inlector Testing/Cleaning
High-Pressure, High-Resistance, High-Pressure, Low-Resistance Ported EFI

Injectors Only
To help diagnose EFI fuel injector problems, use the following troubleshooting chart along with
the Rotunda Fuel Injector Tester/Cleaner 113-00001 or equivalent.
The majority of fuel injector problems are due to plugged injectors caused by fuel deposits.
These injectors can be cleaned and restored back to their normal operating condition.
If injectors will not clean, or have another of the listed problems, injectors must be tested
before replacement.
FUEL INJECTOR TROUBLESHOOTING CHART

FOR HIGH-PRESSURE, HIGH-RESISTANCE AND HIGH-PRESSURE LOW-RESISTANCE
PORTED EFI SYSTEMS ONLY
Fuel Injector
Symptom Cause Corrective Action
Failure Mode .
Tip deposits.
Rough Idle, Hard Start, Lean injector. Clean injectors.
(Plugged)
Internal Test/replace if
Hot/Cold
contamination. necessary.
Te9t/replace if
Rich injector. Stuck open. (Leaks)
necessary.
Test/replace if
Injector will not pulse. Short or open circuit.
necessary.
Tip deposits.
Misses Under Load Lean injector. Clean injectors.
(Plugged)
Hesitates or Stalls on Internal Test/replace if
Acceleration contamination. necessary.
Backfires
Lacks Power
Surges at Steady
Speed
Internal Test/replace if
Gas Smell Injector stuck open.
contamination. necessary.
Injector leaks internally Internal Test/replace if
(into intake manifold). contamination. necessary.
Injector leaks Test/replace if
Defective O-Rings.
externally. necessary.
NOTE: Test and clean injectors using the Rotunda Tester/Cleaner 113-00001 or equivalent.

ALL RIGHTS RESERVED
Carburetors, Th~ottle Bodies and Injectors 455
Fuel Injector Tester/Cleaner

I
The Fuel Injector Tester/Cleaner was designed to facilitate fuel injector servicing by cleaning
and/or testing fuel inj~ctors without removing them from the engine.
NO CLEANING SOLVENT IN TANK DURING INJECTOR TESTING

Fuel Injector Cleaning Instructions
1. Turn shutoff valve at the back of test stand to ON (open) position.
2. Filter (use paint-type filter) and pour clean gasoline into tester fuel tank and fill to lower
fill line for 8 cylinder vehicles (use less for 4 and 6 cylinder vehicles). Add injector cleaner
solvent from lower fill line to upper fill line (7 ounces). Premixed gasoline and cleaner
solvent may be used. Mixture: approximately 1 oz. of cleaner solvent to 7 oz. of unleaded
gasoline per cylinder.
3. Connect power supply line to vehicle battery (red terminal, positive; black terminal,
negative). Red light (on cleaner side) will flash indicating power connection has been
made and that the unit is off.
4. Activate the 10 minute timer switch, check pressure gauge. The gauge should read 38-40
psi. If adjustment is necessary, turn shutoff valve to ON (open) position, for resetting of
regulator. Remove black cap, back-off locknut, turn screw to obtain proper setting and
retighten locknut. Replace cap. Turn unit off.
5. Connect fuel supply hose to outlet and place other end of hose back into tank. Actuate
the 10 minute timer switch and turn the flowmeter selector valve to flowmeter No. 1 and
then to flowmeter No. 2 and back to flowmeter NO.1. Repeat this procedure several
times to eliminate all air from the system. Turn flowmeter selector valve to flowmeter No.
2 for all cleaning applications. This allows maximum flow. Turn unit off.
6. Disconnect engine fuel inlet line at the supply manifold (rail). Connect the supply hose
from cleaning equipment to the fuel inlet.
7. Disconnect engine return line at the supply manifold (rail). Plug the return line. Install the
U-tube (supplied) between the chassis supply line and the chassis return line.
8. Install the turnbuckle loosely between throttle control rod and suitable hook-up point on
vehicle fender wall. Activate the 10 minute timer switch.
I CAUTION 1
Be sure vehicle is in PARK or NEUTRAL position, parking brake on and/or wheels

blocked front and rear.
Start engine and check for leaks.
9. When the engine speed has stabilized, set the idle speed to 2000 rpm with the
turnbuckle.
10. Reset. the remaining 10 minute cycle (automatic). Turn ignition switch to OFF, remove
turnbuckle.

ALL RIGHTS RESERVED
1 F_u_e_l_ID_J_-e_c_to_r_T_e_s_te_r_/_c_le_a_D_e_r 1
11. Disconnect the cleaner supply hose from the fuel supply manifold connection inlet.
Drain and discard remaining mixture from cleaner fuel tank.

12. Turn power switch off and disconnect power supply. Reinstall vehicle fuel lines. Start the
engine and check for leaks.
Install fuel connector retaining clips (N805522 inlet, N805521 outlet). When reinstalling
vehicle fuel lines, lubricate a-rings. Put safety ring onto fuel line connector when
reinstalling vehicle fuel lines on late models equipped with spring lock connectors. Safety
indicator ring will pop off when connection is properly installed. Check for proper "seating
of connection" by using hand force to separate -connection, check for leaks.
Fuel Injector Testing

1. Turn manual shutoff valve of test stand panel to OFF (closed) position.
2. Filter (use paint-type filter) and pour clean gasoline into the tester fuel tank, and fill to
lower fill line for 8 cylinder vehicles, use less for 4 and 6 cylinder vehicles.
DO NOT ADD ANY CLEANER SOLVENT IN TANK FOR TESTING.

3. Connect power supply line to vehicle battery (red terminal, positive; black terminal,
negative). Red light (on cleaner side) will flash indicating power connection has been
made and the unit is off.
4. Activate the 10 minute timer switch, check pressure gauge. The gauge should read 38-40
psi. If adjustment is necessary, turn shutoff valve to ON (open) position, for resetting of
regulator. Remove black cap, back-off locknut, turn screw to obtain proper setting and
retighten lock nut. Replace cap. Turn unit off.
5. Calibrate the tester using the procedure outlined in the instructions; included with the
calibration kit injectors.
NOTE: Calibration decals must be on the flow tubes.

6. Disconnect engine fuel inlet connection at the fuel manifold (rail). Connect the supply hose
from testing equipment to the fuel inlet connection.
7. Disconnect engine fuel return connection at the fuel manifold (rail) from fuel return line.
Plug the return. Install the U-Tube (supplied) between the chassis supply line and the
chassis return line.
f CAUTION I
Be sure vehicle is in PARK or NEUTRAL position, parking brake on and/or wheels
blocked front and rear.
Start engine and check for leaks.
9. Run the engine just long enough (approximately 2 minutes) to eliminate all the air in fuel
supply hose and fuel rail. Shut engine off. Do not shut off tester unit.

ALL RIGHTS RESERVED
10. Select the proper flow range. Turn the flowmeter selection valve to
Flowmeter No. 1 for Blue, Grey or Yellow injectors, or
Flowmeter No. 2 for White, Black, Green or Brown injectors.
The flow band colors correspond to the injector top color. (Color may vary slightly
between manufacturers.) Flowmeter 2B is now available for newly released injectors.
Refer to EFI Application Chart.
11. Install the tester injector harness on the vehicle injectors. Match the injector number on
the harness to that of the cylinder (or use 10 pin connector FA-412) for S.OL engine (or 8
pin adaptor harness No. 6222 for 3.8L).
12. Position injector selector switch to each injector number while pressing fuel injector test
button.
13. Observe the position of the flowmeter float at eye level when the ball stops rising. A float
level within the color code range on the scale indicates a good injector.
14. To confirm initial test readings, a maximum of three testings on the set of the injectors
can be performed restarting the engine.
15. Any injectors removed from an engine should be bench tested to confirm diagnostic
conclusions. A continuity checker FA-407 is provided to check continuity of injector
harness leads between the injector and the ECM unit. Disconnect injector and insert
continuity checker FR-407 into injector plug. Start engine, observe Continuity checker will
blink showing completed circuit for that injector being tested.
NOTE:
a. If the flowmeter readings are high or low on the color code scale, the fuel injectors
should be cleaned.
b. If all the readings are high, there may be' leaky injectors' (one or more). To check for
leaky injectors, observe pressure gauge. It should hold pressure with the fuel pump and
manual shut off valve. If there is a pressure drop, detect the leaky injector by observing
flowmeter (the leaky injector shows less flow). If this is not possible, remove all injectors
and test individually. Refer to Bench Testing procedure.
c. 'f fuel injector cleaning is required, turn manual shutoff valve to the ON position. Refer to
Fuel Injector Cleaning Procedure.
d. Testing may be performed before or after cleaning process.
Fuel Injector Bench Testing Procedure

Individual Injector Performance and Leakage Testing.
1. Check that the manual shutoff valve at the back of test stand is in ON (open) position.
2. Fill the Tester/Cleaner fuel tank with several ounces of clean, fresh gasoline.
3. Connect the fuel supply hose FA-402 to the fuel supply outlet and to the Bench Fixture.
4. Insert injector to be tested in Bench Fixture.
5. Connect the NO.1 tester harness connector to the fuel injector. Turn the injector selector
switch to No. 1 position.
6. Direct the injector nozzle into the tester fuel tank.

ALL RIGHTS RESERVED
7. Connect the power supply leads to the battery, observing correct polarity.
8. Activate the 10 minute timer switch and check for leaks.
9. Press the injector test switch and the purge switch together for about 30 seconds to
eliminate air from the supply hose and injector.
10. No leakage from the fuel injector nozzle tip should be visible. Replace any leaking
injector.
11. Press injector test switch to test injector, observe float in flowmeter.
12. Check the flowmeter readings and record all test results.
Factors That Cause False Flow Readings
Air bubbles in the system fuel lines.
Excessive amount of cleaner solution in the system.
Fuel pressure other than recommended 39-40 psi for all high-pressure EFI vehicles. Refer to
Section 11 including the fuel pressure regulator diagnostic.
Low voltage from a weak power source.
Heat from prolonged engine running. Cool engine before retesting.
Use the following approved solvents: D9AZ-19579-B or E6AZ-19579-C only.
NOTE: All multiport (EFI) injectors should be tested at 40 PSI regardless of vehicle
system operating pressure.
Service Maintenance
Periodically the flowmeters need cleaning. Follow the Matheson Instrument instructions
enclosed or flush unit with denatured alcohol, allow the fluid to recirculate several minutes,
switching flowmeter selection valve from No. 1 to No. 2 several times while unit is operating.
Discard fluid. Reflush again using above procedure, discard fluid. Change filter.
To gain access to filter located under the front cover, unscrew and remove the cover access
bolts, each side and slide the cover off. Replace filter with in-line type filter. Change filter
frequently.
When new injector applications are released, new calibrated flow tubes are available from
Triangle Special Products Group. This unit is suitable for conversion for K-Jetronic fuel
systems. If K-Jetronic fuel system cleaning is desired, a modification kit is available from
Triangle Special Products Group.
NOTE: Triangle Special Products Group (Miller Special Tools) is a division of The
Triangle Corporation.

ALL RIGHTS RESERVED
EFI Injectors
Model Engine Source

Part Number Connector Color
Year Application Source #/HR
1987 1.9L Car Bosch (19) E6EE-9F593-AB White
2.3L T/C Car OKK (35) E5ZE-9F593-AB Brown
2.3L OHC Car NO (14) E59E-9F593-AB Gray
2.3L OHC Truck NO (14) E59E-9F593-AB Gray
2.9L Truck Bosch . (14) E70E-9F593-BB Gray
3.0L Car NO (14) E59E-9F593-AB Gray
3.0L Truck NO (14) E59E-9F593-AB Gray
4.9L Truck Bosch (14) E67E-9F593-BB Gray
5.0L Car Bosch/Ford/NO (14) E67E-9F593-BB Gray
5.0L HO Car NO (19) E6TE-9F593-AB Yellowish Orange
5.0L Truck Bosch/OKK (19) E5TE-9F593-BB/AB Yellowish Orange
7.5L Truck Bosch (24) E7TE-9F593-BB

2.3L T/C Car OKK (35) , E5ZE-9F593-AB Brown
2.3L HSC Car Bosch (14) *E67E-9F593-BB Gray
2.3L Truck NO (14) . E59E-9F593-AB Gray
3.8L Car Bosch (14) E67E-9F593-BB Gray
4.9L Truck Bosch/Ford (14) * E67E-9F593-BB Gray
5.0L Car Ford (14) E67E-9F593-BB Gray
5.0L HO Car NO/OKK (19) E6TE-9F593-AB Yellowish Orange
5.0L Truck Bosch/OKK (19) E5TE-9F593-AB Yellowish Orange
5.8L Truck Bosch (19) E5TE-9F593-AB Yellowish Orange
7.5L Truck Bosch (24) E8TE-9F593-BC Blue

2.3L T/C Car OKK (35) E5TE-9F593-AB Brown
2.3L HSC Bosch (14) E67E-9F593-AB Gray
3.8L Car Bosch (14) E67E-9F593-AB Gray
3.8L SIC Car Bosch (30) E9SE-9F593-BB Red
4.9L Truck Ford (14) E67E-9F593-BB Gray
E67E-9F593-BB
5.0L Car Ford/NO (14) Gray
E59E-9F593-AB
5.0L HO Car OKK (19) E6TE-9F593-AB Yellowish Orange
5.0L Truck OKK (19) E5TE-9F593-AB Yellowish Orange
5.8L Truck OKK/Bosch (19) E5TE-9F593-BB/AB Yellowish Orange
7.5L Truck Bosch (24) E8TE-9F593-BB Light Blue

ALL RIGHTS RESERVED
EFI Injectors
Model Engine Source

Part Number Connector Color
Year Application Source #/HR
2.3L HSC Bosch (14) E67E-9F593-AB Gray
*ORI 2.3L HSC NO (14) F03E-9F593-AA Gray
3.8L Car Bosch (14) E67E-9F593-BB Gray
*ORI 3.8L Car Bosch (14) FOSE-9F593-AA Gray
3.8L SIC Car Bosch (30) E9SE-9F593-BB Red
4.0L Truck Bosch (19) 90TF-9F593-AA Black
4.9L Truck Ford (14) E67E-9F593-BB Gray
E67E-9F593-BB
5.0L Car Ford/NO (14) Gray
E59E-9F593-AB
5.0L HO Car OKK (19) E6TE-9F593-AB Yellowish Orange
5.0L Truck OKK (19) E5TE-9F593-AB Yellowish Orange
5.8L Truck Bosch/OKK (19) E5TE-9F593-BB/AB Yellowish Orange
*ORI 5.8L Truck OKK (19) FOTE-9F593-C3A Yellowish Orange
7.5L Truck Bosch (24) E8TE-9F593-BB Lt. Blue
NOTE: * Deposit Resistant Injector

ALL RIGHTS RESERVED
SECTION 5
Catalyst and Exhaust Systems
Contents
System Description 5-1
Catalytic Converter System 5-1
Exhaust Heat Control Valve 5-2
System Diagnosis 5-3

ALL RIGHTS RESERVED
Catalyst and Exhaust Systems 5-1
System Description
Catalytic Converter System
The engine exhaust consists mainly of Nitrogen (N 2), however, it also contains Carbon .
Monoxide (CO), Carbon Dioxide (C02), Water Vapor (H 20), Oxygen (02), Nitrogen Oxides
(NOx), and Hydrogen (H 2) as well as various, unburned Hydrocarbons (HC). Three of these
exhaust components - CO, NOx, and HC - are major air pOllutants, so their emission to the
atmosphere has to be controlled.
The catalytic converter, mounted in the engine exhaust stream, plays a major role in the
emission control system. The converter works as a gas reactor, and its catalytic function is to
speed up the heat p~oducing chemical reaction between the exhaust gas components in order
to reduce the air pollutants in the engine exhaust. The catalyst material, contained inside the
converter, is made of a ceramic substrate that is coated with a high surface area alumina and
i~pregnated with catalytically active, precious metals (Figure 1).
MIXING CHAMBER
(MIDBED)
EXHAUST GASES
FROM ENGINE
FLOW
A4491..c
Figure 1 Dual Catalytic Converter
It is the surface of the catalyst material that plays a major role in the heat producing chemical
reaction. There are basically three types of catalysts:
1. The conventional oxidation catalyst (COC), containing Platinum (Pt) and Palladium (Pd), is
effective for catalyzing the oxidation reactions of HC and CO.
2. The three-way catalyst (TWC), containing Platinum (Pt) and Rhodium (RH) or Palladium
(Pd) and Rhodium (RH), is not only effective for catalyzing the oxidation reactions of HC
and CO, but it also catalyzes the reduction of NOx.

ALL RIGHTS RESERVED
5-2 Catalyst and Exhaust Systems
System Description
3. The Light Off Catalyst (LaC) is a single-bed converter. It is arranged in series with the
main catalytic converter assembly of COC and/or TWC as the aft member(s). This
converter is designed to perform the very specialized function of exhaust emission control
during engine warm-up when the main converter(s) is not yet at the temperature required
for maximum efficiency. The LaC is designed to operate effectively in the high
temperature environmental conditions that exist near the manifold flange. The LaC was
designed with a minimum heat sink effect and; therefore, provides minimum delay in warm-
up of the main catalytic converter(s).
The catalytic converter assembly consists of a structured shell containing a monolithic

substrate - a ceramic, honeycomb construction. In order to maintain the converter's feed gas
(exhaust) oxygen content at a high level to obtain the maximum oxidation for producing the
heated chemical reaction, the oxidation catalyst requires the use of a secondary air source,
and this is provided by the pulse air or thermactor air injection systems.
The catalytic converter system is protected by several devices that block out the secondary air
supply from the thermactor air injection system when the engine is laboring under any
abnormal hot or cold operating situation.
Depending on the engine calibration, these block-out devices are functional under one or more
of the following conditions:
Cold engine operation with rich choke mixture.
Abnormally high engine coolant temperatures above 107C (225F), which may result from a
condition such as an extended, hot idle on a hot day.
Wide-open throttle.
Engine deceleration.
Extended idle operation.

A complete description of the design and operation of these block-out devices can be found
in Thermactor Systems, Section 10.
Exhaust Heat Control Valve

Exhaust Heat Control Valve, Bimetal Type
The valve is normally in the closed position, engine cold and not running, to divert exhaust
gases to the intake manifold riser pad. When the engine is started, the heat from the exhaust
gases actuates the bimetal spring which opens the valve. As operating temperatures are
reached, the valve will remain open. The valve, when cold, will also open at high engine
speeds, due to the action of the exhaust gas on the unbalanced valve plate.
A. Inspect valve assembly for any abnormal condition. Service or replace as necessary.
B. Lubricate the valve with COAZ-19A501-A or C4AZ-19A501-A graphite lube or equivalent.
C. Check valve and thermostatic spring operation by manually rotating the valve shaft. Valve
must be free and return to the closed position when cold (Rotunda Choke Tester Model
090-00001 or equivalent may be used if necessary to cool bimetal).
Vacuum Operated Heat Control Valve
Refer to Components, Section 3 for description and operation.

ALL RIGHTS RESERVED
.Catalyst and EXha~st Systems 53
System Diagnosis
A restricted or blocked exhaust system usually results in loss or lack of power or popping
through the carburetor. Verity that the condition is not caused by ignition or timing problems,
then proceed with diagnosis using the following procedure.
'TEST STEP RESULT ~ ACTION TO TAKE
80 I VISUAL INSPECTION
Visually inspect exhaust system. Yes ~ GO to [!i].

Is exhaust system visually OK?
No ~ REPLACE any
collap.sed exhaust
components. If problem
is not corrected, GO to
1811.
81 I VACUUM TEST
Attach vacuum gauge to intake manifold vacuum Yes ~ No restriction in

source. exhaust system.
REFER to Section 2,
Hook up tachometer. Diagnostic Routine 209,
Lack of Power.
Start engine and gradually increase speed to 2000
rpm with transmission in NEUTRAL.
Is the manifold vacuum above 16 inches of
No ~ GO to 1821.
mercury?
82 I VACUUM TEST - EXHAUST DISCONNECTED
Turn engine Off. Yes ~ GO to \831.

Disconnect exhaust system at exhaust manifold(s).
No ~ GO to 1841.
Repeat vacuum test.
Is the manifold vacuum above 16 inches of
mercury?

ALL RIGHTS RESERVED
5-4 Catalyst and Exhaust Systems
System Diagnosis
TEST STEP RESULT ~ ACTION TO TAKE
83 IVACUUM TEST -
ON/MUFFLER(S) OFF
CATALYTiC CONVERTER(S)
Turn engine Off. Yes ~ REPLACE muffler(s).

Reconnect exhaust system at exhaust manifold(s).
Disconnect muffler(s). No ~ REPLACE catalytic
Repeat vacuum test. converter and inspect
muffler to be sure
Is the manifold vacuum above 16 inches of converter debris has
mercury? not entered muffler.
84 I EXHAUST MANIFOLD RESTRICTED
Remove the exhaust manifold(s). Inspect the ports Yes ~ REMOVE casting flash.
for casting flash by dropping a length of chain If flash cannot be
into each port. removed, REPLACE
NOTE: Do not use a wire or light to check exhaust manifold(s).
ports. The restriction may be large
enough for them to pass through but
small enough to cause excessive back
No ~ REFER to Section 2,
Diagnostic Routine 209,
pressure at high engine rpm. Lack of Power.
Is a restriction present?

ALL RIGHTS RESERVED
SECfION 6
Exhaust Gas Recirculation

(EGR) Systems
Contents
System Descriptions 6-1
Vacuum Operated EGR Systems 6-1
Pressure Feedback Electronic (PFE) EGR System 6-1
Electronic EGR System 6-3
Back Pressure Variable Transducer (BVT) EGR System 6-6
Integral Back Pressure Transducer EGR System 6-8
Valve and Transducer EGR System 6-9
Other EGR System Components 6-10
EGR Vacuum Regulator 6-10
EGR Solenoid Vacuum Valve Assembly 6-11
Solenoid Vacuum Valve Assembly 6-11
EGR Load Control (WOT) Valve 6-12
Vacuum Control Valve 6-12
Vacuum Reservoir 6-13
Vacuum Check Valve 6-13
Diagnosis By Symptom 6-14
Functional Diagnosis 6-20
Back Pressure Variable Transducer (BVT) System 6-20
Integral Back Pressure (IBP) Transducer EGR Valve 6-21
Ported EGA Valve 6-22
Electronic EGA (EEGR) Valve 6-23
Valve and Transducer Assembly 6-24

ALL RIGHTS RESERVED
Exhaust ~as Recirculation (EGR) Systems 61
. "
System Descriptions
VACUUM OPERATED EGR SYSTEMS

The Exhaust Gas Recirculation (EGR) System is designed to reintroduce exhaust gas into the
combustion cycle lowering combustion temperatures and reducing the formation of Nitrous
Oxide. .
There are five basic types of EGR systems:
The PFE - EGR System (9J460 + 90475)
The Electronic EGR Valve (9F483)
The Back Pressure Variable Transducer (9J431 + 90475)
The Integral Back Pressure Transducer EGR Valve (90448)
The Valve and Transducer Assembly EGR Valve (9H495)
The amount of exhaust gas reintroduced and the timing of the cycle varies by calibration and
is controlled by various factors such as engine speed, engine vacuum, exhaust system back
pressure, coolant temperature and throttle angle depending on the calibration. All EGR valves
are vacuum actuated. The vacuum diagram is shown on the emission decal for each
calibration.
PRESSURE FEEDBACK ELECTRONIC (PFE) EGR SYSTEM

PFE is a subsonic closed loop EGR system that controls EGR flow rate by monitoring the
pressure drop across a remotely located sharp-edged orifice. The system uses pressure a
transducer (-9J460-) as the feedback device and controlled pressure is varied by valve
modulation using vacuum output of the EVR solenoid (-9J459-). With PFE system, the EGR
valve only serves as a pressure regulator rather than a flow metering device.
ANALOG VOLTAGE r - - - - __
INPUT
__- - - - - f ~...;....;...;;;...;.,;;,,;=-..~
t.
INTAKE
FLOW

CONTROLLED
PRESSURE
METERING ORIFICE
EXHAUST PRESSURE
EXHAUST
FLOW
A11509-B
Figure 1 Typical Pressure Feedback Electronic (PFE) EGR System

ALL RIGHTS RESERVED
6-2 Exhaust Gas Recirculation (EGR) Systems
System Descriptions
System Components
PFE EGR Valve-90460 (90475)
The Pressure Feedback Electronic (PFE) EGR valve is a conventional ported EGR valve. The
service replacement for this valve is (-90475-) which does not include the pick up tube/plug.
The original pick up tube/plug should be used with the new service valve (-90475-).
A9362-B
Figure 2 Typical Pressure Feedback

Electronic EGR Valve
PFE EGR Transducer - 9J460
The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure
signal into a proportional analog voltage which is digitized by the EEC-IV processor. The EEC-
IV processor uses the signal received from the PFE transducer to complete the optimum EGR
flow.
A9363B
Figure 3 Pressure Feedback Electronic EGR

Transducer

ALL RIGHTS RESERVED
Exhaust Gas Recirculation (EGR) -Systems 6-3
System Descriptions
ELECTRONIC EGR SYSTEM
The Electronic EGA Valve (Figure 4) is required in EEC systems where EGA flow is controlled
according to computer demands by means of an EGA Valve Position (EVP) sensor attached to
the valve.
The valve is operated by a vacuum signal from the electronic vacuum regulator (9J459) which
actuates the valve diaphragm or the dual EGA Solenoid Valves (90474) on 2.3L passenger
cars only. .
As supply vacuum overcomes the spring load. the diaphragm is actuated. This lifts the pintle
off its seat allowing exhaust gas to recirculate (flow). The amount of flow is proportional to the
pintle position. The EVP sensor mounted on the valve sends an electrical signal of its position
to the Electronic Control Assembly (12A650).
EVP
INPUT
o
EXHAUST PRESSURE
EXHAUST ~
FLOW ~
A12757A
Figure 4 Typical Electronic EGR System

ALL RIGHTS RESERVED
System Descriptions
SYSTEM COMPONENTS
Electronic EGR Valve - 9F483 (9H473)
The EGR valve for this system is a vacuum operated EGR valve which maintains a service
flow in the valve seat/pintle area.
The Electronic EGA Valve Assembly (9F483) is not serviceable. The EVP sensor (9G428) and
EGR valve (9H473) must be serviced separately.
EGR VALVE
AND SENSOR
ASSEMBLV
9F483
EGR VALVE
9H473
EGRVALVE
AND SENSOR
ASSEMBLY
IF483
EXHAUST GAS INLET

BASE ENTRY TYPE A7192-e
SIDE (EXTERNAL) ENTRY TYPE
4 A7IIn-D
Figure 5 Electronic EGR Valve - 5.0L Figure 6 Electronic EGR Valve - All
Passenger Car Only Applications Except 5.0L Passenger
Car

ALL RIGHTS RESERVED
Exhaust Gas Recirculation (EGR) Systems 6-5
System Descriptions
EGR Valve Position (EVP) Sensor - 9G428
The EVP Sensor provides the EEC System with a signal indicating position of the EGA valve.
EVP SENSOR
(REMOVABLE)
TYPICAL
LOCAnON
ASSEMBLY
A5932E
Figure 7 EGR Valve Position (EVPj Sensor

ALL RIGHTS RESERVED
66 Exhaust Gas Recirculation (EGR) Systems:
System Descriptions
BACK PRESSURE VARIABLE TRANSDUCER (BVT) EGR SYSTEM
The BVT system is used on 1.9L EFI H.O. passenger car applications. A typical BVT control
system is shown in Figure 8. It consists of three components; a vacuum regulator (9J431),
EGR valve (90475) and a flow control orifice.
The regulator modulates the vacuum signal to the EGR valve using two back pressure inputs.
One input is the standard vehicle back pressure and the other is the back pressure
downstream of the flow control orifice. The control chamber pickup is in the EGR tube and
the flow control orifice is integral with the upstream EGR tube connector.
INTAKE
AIR
EGR VALVE CONTROL VACUUM
OUTPUT
~
w
a:
:::J
(f)
BVT (f)
w
a:
Q.
~
~ 5 Q.
~ ~
:::J
oct
:x:
x
w L..- _
A7244-C
Figure 8 Back Pressure Variable Transducer (BVT) Schematic Diagram

ALL RIGHTS RESERVED
Exhaust Gas Recirculation (E,GR) Systems 6-7
System Descriptions
System Components
Ported EGR Valve - 9D475
The ported EGR Valve is operated by a vacuum signal which actuates the valve diaphragm.
As the vacuum increases sufficiently to overcome the power spring, the valve is opened
allowing EGA flow. The vacuum to the EGR valve is controlled using the BVT (9J431).
OUTLET VALVE INLET

(VALVE HAS TAPERED PINTLE ALSO) .
~
BASE ENTRY. POPPET TYPE A5978-D
Figure 9 Ported EGR Valve (90475)
Back Pressure Variable Transducer (BVT) - 9J431
The BVT controls the vacuum input to the EGR valve based on the engine operating
condition.
VACUUM BLEED HOLE VENTS

UNTil CLOSED BY EXHAUST DIAPHRAGM
BACK PRESSURE WORKING
ON DIAPHRAGM
BLEED AIR IN
"4~~~~~=-==S:::::::S::::::S=:::39~~_ EGR VALVE
CONTROL VACUUM
}~~~~~~&~~~~~~~~.
U EGR VALVE CONTROL
CHAMBER PRESSURE
SPRING-~~~~{/ ~~~~~;:L,_ BLEED HOLE SEAL

c:!~~"~=:::J!!"'''~!:br=s~:t-_ EXHAUST
BACK PRESSURE
E VACUUM SIGNAL
C BACK PRESSURE DOWNSTREAM
OF ORIFICE
B BACK PRESSURE OF VEHICLE
E C B
MOUNTING
POST
A7171-C
Figure 10 EGR Back Pressure Variable Transducer

ALL RIGHTS RESERVED
System Descriptions
INTEGRAL BACK PRESSURE TRANSDUCER EGR SYSTEM
System Components
Integral Back Pressure Transducer EGR Valve - 90448
The Integral Back Pressure Transducer EGR Valve (Figure 11) is used on 5.8L carburetor
passenger cars only. It combines inputs of back pressure and EGR port vacuum into one unit.
The valve requires BOTH inputs to operate. The valve will not operate on vacuum alone.
VACUUM CONNECTION VACUUM CHAMBER

r-------~
VACUUM BLEED HOLE-VENTS
.~~~~ UNTIL CLOSED BY EXHAUST
"- BACK PRESSURE WORKING
ON INNER DIAPHRAGM
~r-- __ OPEN TO
EXHAUST ATMOSPHERIC
BACK PRESSURE PRESSURE
CHAMBER
ORIFICE
e A7178-C
Figure 11 Integral Back Pressure Transducer EGR Valve (90448)

ALL RIGHTS RESERVED
System Descriptions
VALVE AND TRANSDUCER EGR SYSTEM
System Component
EGR Valve and Transducer Assembly - 9H495
The Valve and Transducer Assembly (9H495) which consists of a modified ported EGR valve
and a remote transducer, is used on 6.1 L/7.0L Trucks only (Figure 12). This assembly
operates the same as the Integral Back Pressure Transducer EGR Valve (90448) and is
diagnosed and serviced as an assembly only. Valve function checks are the same as those
for the Integral Back Pressure Transducer EGR Valve.
When servicing the assembly or any related vacuum harness, it is important to ensure proper
orientation of the transducer. The nipple of the transducer attached to the metal tube from the
EGR valve base must point straight down after installation. This allows drainage of exhaust
gas condensation that may accumulate.
A12762-A
F!gure 12 EGR Valve and Transducer

Assembly

ALL RIGHTS RESERVED
System Descriptions
OTHER EGR SYSTEM COMPONENTS
The following components are used in the EGR systems. Detailed descriptions and diagnosis
of these components may be contained in other Sections.
EGR VACUUM REGULATOR-9J459
The EGR Vacuum Regulator (EVR) is an electromagnetic device which controls vacuum output
to the EGR valve. The EVR replaces the EGR Solenoid Vacuum Vent Valve Assembly
(90474). An electric current in the coil induces a magnetic field in the armature. The magnetic
field pulls the disk closed, closing the vent and increasing the vacuum level. The vacuum
source is either manifold or vacuum. As the duty cycle is increased, an increased vacuum
signal goes to the EGR valve.
Figure 13 EGR Vacuum Regulator
Diagnosis
Refer to the EEC-IV Quick Test, Section 14.

ALL RIGHTS RESERVED
Exhaust Gas Recirculation (EGR) Systems
System Descriptions
EGR SOLENOID VACUUM VALVE ASSEMBLY-9D474
The dual EGA Solenoid Valve Assembly is used only in 2.3L Mustang applications to control
the vacuum input to the EGA valve.
Pl"......_ - _ VENT
FILTER
SOL V
OE-ENERGIZED ENERGIZED
EGR VALVE EGR VALVE
MAINTAIN EGR FLOW INCREASE EGR FLOW OECREASE EGR FLOW
EXISTING VACUUM IS TRAPPED IN LINE, INCREASED VACUUM OPENS EGR VALVE FOR EXISTING VACUUM IN LINES IS VENTED TO
HOLDING EGR VALVE IN SAME POSITION MORE EGR FLOW ATMOSPHERE A5931-E
Figure 14 EGR Solenoid Valve Assembly-Dithering Type
EGR SOLENOID VACUUM VALVE ASSEMBLY-9D474
This Solenoid is used on 1.9L EFI-HO applications to cut off the vacuum to the EGA valve.
BLADE TYPE
TERMINALS OR MOLDED
CONNECTOR
INLET PORT SOL V

A68470C
Figure 15 Typical Solenoid Valve

Assembly - Normally Closed

ALL RIGHTS RESERVED
System Descriptions
EGR LOAD CONTROL (WOn VALVE-9F424
This valve dumps EGA vacuum at or near WOT and is used on 6.1 L/7.0L Truck and 5.8L
Police applications.
The normal path between Ports A and B is vented to atmosphere when sufficient vacuum is
applied to Port C.
ATMOSPHERIC
VENT HOLES
LCV
A5967-D
Figure 16 EGR Vacuum Load Control (WOT)

Valve
VACUUM CONTROL VALVE-8A564
The Vacuum Control Valve controls vacuum to the EGA valve during engine warm-up. The
Vacuum Control Valve is used only for 5.8L Police and 6.1 L/7.0L Truck applications.
........~_C
-......,.- A
3-PORT
VCV
A13534-A
Figure 17 Vacuum Control Valve

ALL RIGHTS RESERVED
Exhaust Gas Recirculation (EGR) Systems 6-1~
System Descriptions
VACUUM RESERVOIR - 9E453

The Vacuum Reservoir (Figure 18) stores vacuum and provides "muscle" vacuum. It prevents
WITHOUT CHECK VALVE ORIENTATION

POST
CHECK VALVE
AND VACUUM
SUPPLY
WITH CHECK VALVE
~. ~
VRESER
A6069-D
Diagnosis
VACUUM CHECK VALVE-12A197

A vacuum check valve (Figure 19) blocks airflow in one direction. It allows free airflow in the
- - - . . . . DIRECTION OF FREE AIRFLOW
~+:'1TIr VACUUM SIDE

- BLACK
~
VCKV
A12789-A
Diagnosis

ALL RIGHTS RESERVED
614 Exhaust Gas Recirculation (EGR) Systems
Diagnosis By Symptom
SYMPTOM POSSIBLE SOURCE ACTION

Rough Idle Cold EGR valve malfunction. Run EEC-IV Quick Test. Refer to
Section 14..
BVT malfunction. Perform BVT diagnosis.
EGR flange gasket leaking. Replace flange gasket and tighten
valve attaching nuts or bolts to
specification.
EGR valve attaching nuts or bolts Replace flange gasket and tighten
loose or missing. valve attaching nuts or bolts to
specification.
EGR or VCV malfunction. Perform EGR or VCV diagnosis.
Load control (WOT) valve Perform load control (WOn valve
malfunction. diagnosis.
Vacuum leak at EVP sensor. Replace O-ring seal and tighten
EVP sensor attaching nuts to
specification.
EGR valve contamination. Clean EGR valve.
Curb idle speed too high or low. Reset according to Section 4.
Rough Idle Hot EGR valve malfunction. Run EEC-IV Quick Test. Refer to
Section 14.
specification.
specification.
Load control (WOT) valve Perform load control (WOT) valve
specification.

ALL RIGHTS RESERVED
Exhaust Gas Recirculation (EGR) Systems 615

Rough Running, Surge, EGA valve malfunction. Perform EGA valve diagnosis.
Hesitation, Poor Part Throttle
Performance -Cold
EGA flange gasket leaking. Aeplace flange gasket and tighten
specification.
EGA valve attaching nuts or bolts Aeplace flange gasket and tighten
specification.
EGA solenoid malfunction. Aun EEC-IV Quick Test. Aefer to
Section 14.
EGA or VCV malfunction. Perform EGA or VCV diagnosis.
Vacuum leak at EVP sensor. Aeplace O-ring seal and tighten
specification.
EGA valve contamination. Clean EGR valve.
Ignition timing too low. Reset to specification shown on
emission decal.
Rough Running, Surge, EGA valve malfunction. Perform EGA valve diagnosis.
Hesitation, Poor Part Throttle
Performance -Hot
EGA flange gasket leaking. Aeplace flange gasket and tighten
specification.
EGA valve attaching nuts or bolts Replace flange gasket and tighten
specification.
EGA or VCV malfunction. Perform EGA or VCV diagnosis.
EGA valve contamination. Clean EGR valve and if necessary,
replace EGA valve.
specification.
Insufficient exhaust back pressure Check exhaust system for leaks.
to activate valve.
emission decal.

ALL RIGHTS RESERVED
'1. . . D_i_ag_D_o_S_i_S_B_y_S_y_m_pt_o_m _

Engine Stalls On Deceleration- EGR valve malfunction. Perform EGR valve diagnosis.
Hot and Cold
BVT malfunction. Perform BVT functional test.
specification.
specification.
EGR solenoid malfunction. Run EEC-IV Quick Test. Refer to
Section 14.
EGR valve contamination. Clean EGR valve and if necessary,
replace EGR valve.
Curb idle speed too low. Reset according to Section 4.
emission decal.

ALL RIGHTS RESERVED

Engine Spark Knock or Ping . EGA malfunction. Perform EGR valve diagnosis.
specification.
specification.
EGA solenoid malfunction. Run EEC-IV Quick Test. Refer to
Section 14.
Blocked or restricted passages in Clean passages in EGR spacer
valve or spacer. and EGR valve.
Vacuum leak at EVP .sensor. Replace a-ring seal and tighten
specification.
to actuate valve.
Ignition timing too high. Reset to specification shown on
emission decal.
Air cleaner temperature vacuum Perform air cleaner temperature
switch (TVS) malfunction. switch (TVS) diagnosis, refer to
Section 3.
Engine Stalls At Idle - Cold EGR valve malfunction. Perform EGR valve diagnosis.
specification.
loose or missing. . valve attaching nuts or bolts to
specification.
Section 14.
EGR or PVS malfunction. Perform EGR or PVS diagnosis.
EGA valve contamination. Clean EGA valve.
Load control (WOn valve Perform load control (WOn valve
Curb idle speed too low. Reset according to Section 4.
emission decal.

ALL RIGHTS RESERVED

Engine Stalls At Idle - Hot EGR valve malfunction. Perform EGR valve diagnosis.
specification.
specification.
EGR valve contamination. Clean EGR valve and if necessary,
replace EGR valve.
specification.
Section 14.
emission decal.
Low Power at Wide-Open EGR valve malfunction. Perform EGR valve diagnosis.
Throttle
specification.
specification.
Section 14.
emission decal.

ALL RIGHTS RESERVED

Engine Starts But Will Not EGR valve malfunction. Perform EGR valve diagnosis.
Aun -Engine Hard To Start Or
Will Not Start
specification.
specification.

Section 14.
EGR or VCV malfunction. Perform EGR or VCV diagnosis,
. refer to Section 3.
Vacuum leak at EVP sensor. Replace a-ring seal and tighten
specification.
Poor Fuel Economy EGA valve malfunction. Perform EGR valve diagnosis.
EGA flange gasket leaking. Replace flange gasket and tighten
specification.
I loose or missing. attaching nuts or bolts to
specification.
EGR solenoid malfunction. ~ Run EEC-IV Quick Test. Refer to
Section 14.
EGR or PVS malfunction. Perform EGR or PVS diagnosis.
Blocked or restricted EGR Clean passages in EGA spacer
passages in valve or spacer. and replace EGR valve.
malfunction. diagnosis.'
Vacuum leak at EVP sensor. Replace a-ring seal and tighten
specification.
to activate' valve.
emission decal.

ALL RIGHTS RESERVED
Functional Diagnosis
AA
BACK PRESSURE VARIABLE
TRANSDUCER (BVT) SYSTEM
9J431
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal
operating temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a
hand vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
If idle speed drops more than 100 rpm or if engine stalls, perform the next step.
Otherwise, for vacuum leak at EGR valve, replace the valve.
If EGR passages are blocked, clean the EGR valve using (Rotunda) 021-80056 EGR
valve cleaner or equivalent.
Remove the vacuum from the EGR valve. If idle speed does not return to normal
( 25 rpm), check for contamination, clean the valve.
If symptom still exists, replace the EGR valve.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. Disconnect the vacuum connection at the 9J431 Back Pressure Variable Transducer (BVT).
12. Gently blow into the hose to Port C until the relief valve closes and at the same time
apply 5-10 inches of mercury vacuum to Port E with a hand vacuum pump. Port E should
hold vacuum as long as there is pressure on Port C.
13. Apply a minimum of 5-10 inches of mercury vacuum to Ports Band C using a hand
vacuum pump. Ports 8 and C should hold vacuum.
14. Replace the BVT if any of the Ports do not hold vacuum.
15. Reconnect the vacuum at the BVT.
16. If neither the EGR valve nor the BVT were replaced, the system is OK. Refer to the
Diagnostic Routines in Section 2.

ALL RIGHTS RESERVED
INTEGRAL BACK PRESSURE (IBP)

TRANSDUCER EGR VALVE
90448
I WARNING I
DO NOT USE ROTUNDA EGR CLEANER (021-80056) ON THIS VALVE.
2. Make certain there. is no vacuum to the EGR v~lve at idle with the engine at normal
4. Plug the tailpipe(s) to increase the exhaust system back pressure, leaving a 1/2-inch
diameter opening to allow exhaust gases to escape.
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe idle speed. If necessary,
adjust idle speed according to Section 4.
.,. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a
8. When vacuum is applied to the EGR valve and any of the following occur, replace the
valve:
Engine does not stall.
Idle speed does not drop more than 100 rpm.
Idle speed does not return to normal ( 25 rpm) after the vacuum is removed.
9. If the EGR valve is not replaced, reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum'supply hose.
11. Remove the tailpipe plug(s).
12. The EGR system is OK, refer to the Diagnostic Routines in Section 2.

ALL RIGHTS RESERVED
Functional .Diagnosis
PORTED EGR VALVE
90475/90460 90475
3. Install a tachometer. Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
8. When vacuum is fully applied to the EGR valve:
If idle speed drops more than 100 rpm or if engine stalls, perform the next step.
Otherwise, for vacuum leak at EGR valve, replace the valve.
If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve
cleaner.
Remove the vacuum from the EGR valve. If idle speed does not return to normal
( 25 rpm), check for contamination, clean the valve.
Make sure there is no sand left in the valve or pick-up tube. Replace the valve if
necessary.
9. Reconnect the idle air bypass valve electrical connector.

-
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.

ALL RIGHTS RESERVED
~.
"~
~.
ELECTRONIC EGR (EEGR) VALVE l .
9F483 9F483
2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the
engine at normal operating temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small
vacuum signal. This signal should be less than 1.0 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.,
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1 ;9L EFI engines only).
6. Start engine, idle with transmission in NEUTRAL and observe the engine idle speed. If
8. When vacuum is applied to the EGR valve and any of the following occur:
Then:
For vacuum leak at EGR valve, replace the valve.
~
Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve
cleaner or equivalent.
Make sure there is no sand left in the valve.
Replace the EGR valve if necessary.
9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR
vacuum supply hose.
10. If EGR system is OK, replace EVPsensor if Continuous Code 32 is present. If Continuous
Code 32 is not present, go to Diagnostic Routines in Section 2.

ALL RIGHTS RESERVED
VALVE AND TRANSDUCER ASSEMBLY
9H495
4. Plug the tailpipe(s) to increase the exhaust system back pressure, leaving a 1/2-inch
diameter opening to allow exhaust gases to escape.
5. Remove the vacuum supply hose from the Exhaust Back Pressure Transducer nipple and
plug the hose. Do not disconnect the transducer from the EGR valve.
7. Slowly apply 5-10 inches of mercury vacuum to the Back Pressure Transducer vacuum
nipple using a hand vacuum pump, Rotunda 02100014 or equivalent.
8. When vacuum is applied to the Back Pressure Transducer and any of the following occur:
Then:
Check for contamination.
Disconnect the transducer from the pick-up tube and clean the valve using Rotunda
021-80056 EGR valve cleaner or equivalent.
Make sure no sand (grit) is in the valve or pick-up tube.
If symptom still exists, replace EGR valve.
If there is a vacuum leak at the EGR valve, replace the valve.
9. Reconnect the vacuum supply hose to the Exhaust Back Pressure Transducer, remove the
tailpipe plug(s).
10. If EGR system is OK, refer to the Diagnostic Routines in Section 2.
ROTUNDA EQUIPMENT
Model Description
021-00014 Vacuum Pump
059-00010 Tachometer
021-80056 EGA Valve Cleaner

ALL RIGHTS RESERVED
SECTION 7
Evaporative
Emission Systems
Contents
Air Cleaner Purge Evaporative Emission System 7-1
Carbureted Engine Purge System 7-2
EEC-IV Purge System (CFI and EFI) 7-3
Purge Port System 7-4
Combined Purge Port and EEC-IV Purge System 7-5

ALL RIGHTS RESERVED
_________S_ys_t_e_m_,D_e_s_c_n_ep_t_i_O_D 1
Air Cleaner Purge Evaporative Emission System

Fuel Tank Venting
Fuel vapors trapped in the sealed fuel tank are vented through the orificed vapor valve
assembly in the top of the tank. The. vapors leave the valve assembly through a single vapor
line and continue to the carbon canister (located in the engine compartment or along the
frame rail), for storage, until they are purged to the engine for burning.
Carburetor Venting
If the engine is equipped with a carburetor, the vapors from the fuel bowl are vented to the
carbon canister by a second tube to the carbon canister.
NOTE: To ensure efficient flow of vapors, the line from the carburetor bowl should have
a continuous downhill slope to the' canister.
Canister Purging
Purging the carbon canister removes the fuel vapor stored in the carbon canister. With an air
cleaner purge system, vapors flow from the carbon canister to the air cleaner and into the
engine.
FROM
FUEL
TANK
VENT
A9397-A
Figure 1 Typical Air Cleaner Purge Evaporative Emission System

ALL RIGHTS RESERVED
7..2 Evaporative Emission Systems
1 S_ys_t_e_m_D_e_s_c_r_iP_t_i_O_D _
Carbureted Engine Purge System
Fuel Tank Venting
assembly in the top of the tank. The vapors leave the valve assembly through a single vapor
Carburetor Venting
Carburetor vapors from the fuel bowl are vented to the carbon canister. The flow is controlled
by a fuel bowl solenoid vent, thermal vent valve, or vacuum thermal bowl vent valve located
in the carburetor bowl vent line.
a continuous downhill slope to the canister.
Canister Purging
Purging the carbon canister removes the fuel vapor stored in the carbon canister. The flow of
vapors from the canister to the engine is controlled by a purge solenoid or a vacuum
controlled purge valve. Purging occurs when the engine is at operating temperature and off
idle.
Figure 2 Typical Purge Evaporative Emission for Carbureted Engines

ALL RIGHTS RESERVED
Evaporative Emission Systems 7-3
System Description
EECIV Purge System (CFI and EFI)
Fuel Tank Venting
Canister Purging
Purging the carbon canister removes the fuel vapor stored in the carbon canister. With an
EEC-IV controlled purge system, the flow of vapors from the canister to the engine is
controlled by a purge solenoid or vacuum controlled purge valve. Purging occurs when the
engine is at operating temperature and off idle.
VACUUM
PURGE
VALVE
CARBON
CANISTER ----~~
A9399-A
Figure 3 Typical EEC-IV Purge Evaporative Emission System - CFI and EFI

ALL RIGHTS RESERVED
74 Evaporative Emission Systems
System Description
Purge Port System

Fuel Tank Venting
Carburetor Venting
If the engine is equipped with a carburetor, the vapors from the fuel bowl are vented to the
carbon canister. The flow is controlled by a fuel bowl solenoid vent valve, thermal vent valve,
or vacuum thermal bowl vent valve located in the carburetor bowl vent line.
a continuous downhill slope to the canister.
Canister Purging
Purging the carbon canister removes the fuel vapors stored in the carbon canister. With a
purge port system, the vapors flow from the carbon canister to the carburetor or throttle body.
FUEL VAPOR RETURN

TUBE ASSY
A9400-A
Figure 4 Typical Ported Purge Evaporative Emission System

ALL RIGHTS RESERVED
System Description
Combined Purge Port and EEC-IV Purge System
Fuel Tank Venting
Canister Purging
Purging the carbon canister removes the fuel vapor stored in the carbon canister. With a
purge port system, the vapors flow from the carbon canister to the carburetor or throttle body.
With an EEC-IV controlled purge system, the flow of vapors from the canister to the engine is
controlled by a purge solenoid or vacuum controlled purge valve. Purging occurs when the
engine is at operating temperature and off idle.
FUEL VAPOR
RETURN LINE
(PORT PURGE
SYSTEM)
FUEL TANK
~~~~~rr---VAPORHOSE
FUEL VAPOR
RETURN LINE
(EEC-IV PURGE
SYSTEM)
A11616-S
Figure 5 Typical EEC-IV Ported Purge Evaporative Emission System - EFI

ALL RIGHTS RESERVED
7-6 Evaporative Emission Systems
NOTE: If the Evaporative Emission System Is functioning properly, return to Section 2

for further driveabllity complaint diagnosis.
CONDITION POSSIBLE SOURCE * ACTION
Cranks Normally But Slow to 1. Thermostatic Bowl Vent Valve or Go to Diagnostic Test [EEIJ
Start Carburetor Fuel Bowl Thermal and/or ~.
Vent Valve malfunction.
Rough Idle 1. Thermostatic or Vacuum Bowl Go to Diagnostic Test [EEIJ

Vent Valve open or leaking. and/or r:Em .
2. Canister Purge Regulator Valve Go to Diagnostic Test ~ .
open.
3. Carburetor Fuel Bowl Solenoid Go to Diagnostic Test [EE!] .
Vent Valve open.
4. Canister Purge Valve open or Go to Diagnostic Test CEm .
leaking.
Surge at Steady Speed 1- Liquid fuel in Carbon Canister. Replace carbon canister. Check
fuel tank vent system and
carbureto'r for malfunction.
Gas Smell 1. Thermostatic Bowl Vent Valve or Go to Diagnostic Test ~

Carburetor Fuel Bowl Thermal and/or ~.
2. Blockage of Carburetor Bowl Vent Check line for blockage and route
line. with downhill slope to canister.
3. Canister Purge Regulator Valve or Go to Diagnostic Test ~
Canister Purge Valve malfunction. and/or CEm.
4. Carburetor Fuel Bowl Solenoid Go to Diagnostic Test [EE!] .
5. Liquid fuel in Carbon Canister. Replace Canister. Check fuel tank
vent system and carburetor for
malfunction.
6. Fuel Tank Vent System blocked. Check fuel tank vent system.
7. Hole or cut in Carburetor Bowl Visually inspect and replace
Vent Line or Fuel Tank Vent damaged line.
Line.
System component fault in order of occurrence.

ALL RIGHTS RESERVED
'I Diagnosis By Symptom
DIAGNOSTIC TEST
SOURCE COMPONENT DIAGNOSTIC ACTION
NUMBER
Thermostatic Bowl Vent At a temperature of 120F or more, the Vacuum

Valve Vent Valve (E3EE-9G332-AA) should flow air
between carburator port and canister port when no
vacuum is applied to vacuum signal nipple. It should
not flow air with a vacuum applied at the vacuum
signal nipple (Figure 6). At a temperature of 90F or
less, the valve should not flow air or be very
restrictive to airflow.
UPPER BIMETAL
VACUUM SIGNAL
NIPPLE A9390-B
Fig'ure 6 Vacuum/Thermostatic Bowl Vent Valve

ALL RIGHTS RESERVED
7..8 Evaporative Emission Systems
DIAGNOSTIC TEST
NUMBER
Vacuum Bowl Vent The Vacuum Bowl Vent Valve (E3TE-9G332-AA)

Valve should flow air between carburetor port and canister
port when no vacuum is applied to vacuum signal
nipple and should not flow air with a vacuum
applied at the vacuum signal nipple (Figure 7).
UPPER CAP
:u:= I..,-----]~
; ; ~ I - SEAL DISK
T TO
CARBURETOR l:
u C1~
~.
.....
0
ORING SEAL
~ 0 ..
.... 0 0
g I~ TO' 1
~ I g '" CANISTER ~
mil!!!!!S,- ..,r1 '
1/ ~~I"'RESET
___ .............. SPRING
/ \ 'PLUNGER
DIAPHRAGM . _.\
4 ) LOWER CAP
VACUUM SIGNAL
NIPPLE A7193-D
Figure 7 Vacuum Bowl Vent Valve

ALL RIGHTS RESERVED
Evaporative Emission Syst~ms 79
I
DIAGNOSTIC TEST
NUMBER
Canister Purge Valve Important: Never apply vacuum to Port(s) C.

Doing so may dislodge internal
diaghram and valve will be
permanently damaged.
Application of vacuum to Port A (only) should
indicate no flow. If flow occurs, replace valve.
Application of vacuum Port B (only) should indicate
no flow, valve should be closed (all valves except
E5VE-9B963-AA, E4VE-98963-AA, E77E-9B963-AA,
which should indicate slight flow). If valve flows
(except E5VE-AA, E4VE-AA, E77E-AA), replace
valve.
After applying and maintaining 54 kPa (16 in-Hg)
vacuum to port A, apply vacuum to Port 8. Air .
should pass. (Note: Valves E5VE-AA, E4VE-AA,
E77E-AA should indicate higher flow than that
indicated in above test.)
VAPOR INLET PORT
(C)
TO CARBURETOR
FUEL BOWL . (B) TO PURGE SOURCE VACUUM
AND FUEL TANK
VAPOR SOURCE REMOTE MOUNTED
(C)
(A)
TO CARBURETOR
TO SIGNAL VACUUM SOURCE
FUEL BOWL
(B)
(B)
(A) TO PURGE
TO PURGE
TO SIGNAL VACUUM SOURCE
VACUUM
SOURCE VACUUM SOURCE IN-LINE PURGE VALVE
A5925-G
Figure 8 Purge Control Valve

ALL RIGHTS RESERVED
DIAGNOSTIC TEST SOURCE COMPONENT DIAGNOSTIC. ACTION

NUMBER
Carburetor Fuel Apply 9 to 14 volts DC to the Fuel 80wl Vent

Solenoid Vent Valve Solenoid Valve (98982). The valve should close, not
allowing air to pass. If valve does not close or
leaks when voltage and 1 in-Hg vacuum is applied
to carburetor port, replace the valve (Figure 9).
1'fl~~~Z?Z2~~ INLET
FROM
CARBURETOR
~jZZZ.jZ22~Z'J (PORT)
Figure 9 Fuel Bowl Vent Solenoid Valve

ALL RIGHTS RESERVED
Evaporative Emission Systems 7-11
DIAGNOSTIC TEST SOURCE COMPONENT DIAGNOSTIC ACTION

NUMBER
Carburetor Fuel Bowl Fill a container with water. While using a

Thermal Vent Valve thermometer to measure the appropriate temperature
of the water, submerse the Fuel Bowl Thermal Vent
Valve (9E589) in the water for one to two minutes
and try to pull air through the valve using a vacuum
pump. At 90F and below, the vent valve is fully
closed and at 120F and above, the vent valve is
fully open. At temperatures between 90F and
120F, the valve may be open or closed (Figure
10).
A6912-C
Figure 10 Fuel Bowl Thermal Vent Valve

ALL RIGHTS RESERVED

NUMBER
Canister Purge With the Canister Purge Regulator Valve (9C915)

Regulator Valve de-energized, apply 5 in-Hg to "vaccuum source"
port. Valve should not pass air; if it does, replace
valve.
While applying 9 to 14 volts DC to valve, the valve
will open and pass air. If it does not, replace valve
(Figure 11).
-
]
"""'1 t+\
jCARB I
II
r
VACUUM
SOURCE
-"""",.1---,..-_-1IIIIl!-(~~I-S=...L.-..==--t
CANISTER
"
A9386-A
Figure 11 Canister Purge Regulator Valve

ALL RIGHTS RESERVED
SECTION 8
Inlet Air Temperature

Systems
Contents
System Schematics
1.9L CFI, 5.8L (Passenger Car) 8-2
1.9L EFI (Passenger Car) 8-2
1.9L EFI (1990 1/2) 8-3
2.3L EFI (HSC) and 2.3L (OHC) (Mustang) 8-4
3.0L EFI (Taurus/Sable) 8-5
3.8L SEFI (Thunderbird/Cougar) 8-6
3.8L SEFI (Taurus/Sable, Conti.nental) 8-6
3.8L SEFI Supercharged (Thunderbird/Cougar) 8-7
3.8L SEFI Supercharger (Thunderbird/Cougar) :':8-8
2.5L CFI (Passenger Car) ,., 8-9
5.0L SEFI (Passenger Car) 8-9
2.9L EFI (Light Truck) , , 8-10
2.3L EFI Dual Plug (California Only - Light Truck) 8-10
4.0L EFI (Aerostar) 8-10
4.0L EFI (Ranger/Bronco II) 8-11
4.9L EFI, 5.0L EFI, 5.8L EFI, 5.8L E40D EFI,
7.5L E40D EFI, 7.5L EFI (F-Series and Bronco) 8-11
4.9L EFI, 5.0L EFI, 5.8L EFI, 5.8L E40D EFI,
7.5L E40D EFI, 7.5L EFI (E-Series) 8-11
2.3L EFI Dual Plug (49 States - Light Truck) 8-12
1990 3.8L Supercharged Air Induction
(Supercooler and Intercooler) System 8-13
1990 1/2 1.9L EFI (Escort/Tracer) Air Intake System 8-14
All Other Engine Systems 8-15

ALL RIGHTS RESERVED
ALL RIGHTS RESERVED
Inlet Air Temperature Systems 8-1
System Description
All passenger car and light truck engines are equipped with dry-type air cleaners incorporating
a replaceable air filter element. Some air inlet systems use air cleaner assemblies with various
sensors, switches and vacuum motors to control inlet air temperature. In addition, there are
sometimes different sensors present in the air cleaner for other engine control systems.
Some air inlet systems draw air in from a cool air source only, while the rest regulate the air
inlet temperature by drawing air in from a cool air source as well as heated air from a heat
shroud which is mounted on the exhaust manifold. The duct and valve system which regulates
the air flow from these two sources is located either inside the air cleaner, mounted on the
air cleaner, or in one of the remote mounted inlet tubes. The flow is regulated by means of a
door that is operated by a vacuum motor. Operation of the motor is controlled by delay
valves, temperature sensors and other vacuum control systems. All vary with each application
and engine calibration. .
The air inlet tube(s) or fresh air tube is used to direct air into the air cleaner. The air cleaner
assembly consists of a tray that holds .the air filter element, a filter pack to provide filtered air
to the crankcase ventilation hose, and a cover that directs air to the outlet tube(s). The air
outlet tubes direct filtered air from the air cleaner to the throttle body. For the 7.5L engine, an
idle by-pass hose also provides filtered air to the upper intake manifold from the air outlet
tube during engine idle.
1990 1/2 1.9L EFI Escort/Tracer Air Intake System
The air intake system consists of the following components:
A fresh air inlet tube with a side branch resonator.
An air cleaner assembly that consists of a cover and tray assembly and a filter element
attached together with four string clamps. The air cleaner tray is connected to the fresh air
inlet tube. The air cleaner cover has a mass air flow sensor attached to it with a gasket
and four screws. The cover also has an aircharge temperature sensor attached to it.
An air outlet tube with hose clamps that connects the air cleaner to the throttle body.

ALL RIGHTS RESERVED
82 Inlet Air Temperature Systems
II-- S_y_st_e_m_s_c_h_e_m_a_ti_cs ___
The following are schematic representations of some 1990 Passenger Car and TrLick inlet air
systems:
COLD WEATHER MODULATOR (CWM)
~_FRESHAIR
1.9L CFI
~ DUCT AND VALVE ASSY
BIMETAL SENSOR DUCT AND
~
RESONATOR VALVE ASSY
AIR INTAKE I~ ~
TO MANIFOLD _ _~ ,
}-WAAMAIA
ASSY~
VACUUM
~ HEAT SHROUD
rl:
r?\1----_
' "---' ..... A9161D
Figure 1 Air Cleaner and Duct System, Carburetor and Throttle Body Applications-
1.9L CFI, 5.8L (Passenger Car)
THROTILE BODY
VANE AIR FLOW
METER
AIR CLEANER ASSY
r--_ _:y---FRESH AIR

A9165B
Figure 2 Air Cleaner System - 1.9L EFI (Passenger Car)

ALL RIGHTS RESERVED
Inlet Air Temper~ture Systems 83
System Schematics
I
GASKET AIR CLEANER ASSY
AIR INLET
TUBE ASSY
A12758-A
Figure 3 A~r Cleaner System - 1.9L EFI Escort/Tracer (1990 1/2)

ALL RIGHTS RESERVED
8-4 Inlet Air Temperature Systems
System Schematics
COLD WEATHER MODULATOR (CWM)

THROTTLE BODY
/AIR FRESH
VACUUM RETARD
DELAY VALVE
~MAIR AIR CLEANER, DUCT AND VALVE ASSY
VACUUM MOTOR
2.3L OHC EFI (MUSTANG ONLY)
A9162-<:
Figure 4 Air Cleaner System-2.3L EFI HSC (Tempo/Topaz) and 2.3L OHC (Mustang)

ALL RIGHTS RESERVED
System Schematics
FRESH AlA
3.0L ENGINE-TAURUS/SABL.E .
10 THROTTLE BODY
AIR CLEANER ASSY
TOP VIEW
A9163-D
Figure 5 Air Cleaner System - 3.0L EFI (Taurus/Sable)

ALL RIGHTS RESERVED
System Schematics
TO THROTILE BODY
CLOSURE HOSE
TO ENGINE /~~ElO
~
~SENSOR
3.8L SUPER-CHARGE
[(:: f--V _~S$LEANER
l:,. l_-~-~ATOR(MOUNTEO
~'NS'OE RIGHTFENOER)
ONLY
(SEE FIGURE 8)
A9429-B
Figure 6 Air Cleaner System - 3.8L SEFI (Thunderbird/Cougar)
TO FENDER
APRON
A94308
Figure 7 Air Cleaner System - 3.8L SEFI (Taurus/Sable, Continental)

ALL RIGHTS RESERVED
System Schematics
THROTTLE BODY
AND SUPERCHARGE
SYSTEM
A11620-B
Figure 8 Air Cleaner System - 3.8L SEFI Supercharged (Thunderbird/Cougar)

ALL RIGHTS RESERVED
System Schematics
ENGINE CHARGE
AIR COOLER INLET
TUBE ASSY 6F072
NUT
6 REO'D
N801248-S1OO
STUD
1 REO'D
SENSOR
ASSY
12A697
AIR INTAKE
CHARGE THROTTLE
BODY ASSY
9E926
MOO SUPERCHARGER
INLET PLENUM & OUTLET
ADAPTER ASSY 6F076
A12759-A
Figure 9 Supercharger Intercooler System - 3.8L SEFI Supercharger (Thunderbird/Cougar)

ALL RIGHTS RESERVED
Inlet Air Temperature Systems 8..9
System Schematics
I--------------------------------------------
TO HEAT SHROUD
FRESH
AIR
THROTI'LE BOOY "

TO VACUUM MOTOR .......... -
.........
~-
COLD WEATHER MODULATOR (CWMl
(2.5L CFI ONLVl
.....
-I"' ...
(DUCT AND VALVE)
VACUUM RETARD--.Joo\.
, _ - - -
, ....,..--~
AIR CLEANER
~~
ASSV
TOP VIEW
A9837C
Figure 10 Air Cleaner System - 2.5L CFI (HSC) (Passenger Car)
~~
FRESH
MASS AI" FLOW SE""""
(S.OL EFI MUSTANG ONLY) <:.-V
AIR
I TO THROTI'LE BODY
.~
r------ A1R CLEANER ASSY
A9838-D
Figure 11 Air Cleaner System - 5.0L SEFI (Mark VII, Mustang,' Crown Victoria, Grand Marquis,
Lincoln Town Car)

ALL RIGHTS RESERVED
System Schematics
DUCT AND VALVE ASSY
AIR CLEANER
ASSY
TOP VIEW A9164D
AIR CLEANER ASSY
A 11621B
Figure 12 Air Cleaner and Duct System- Figure 14 Air Cleaner System - 2.3L EFI Dual
2.9L EFI (Light Truck) Plug (California Only - Light Truck)
MASS AIR
FLOW SENSOR
. AIR CLEANER ASSY
A12783A
Figure 13 Air Cleaner System - 4.0L EFI (Aerostar)

ALL RIGHTS RESERVED
System Schematics
10 AIR INTAKE TUBE
AIR INTAKE TUBE AND

DUCT ASSY
'TO EXHAUST
MANIFOLD
A12760A
Figure 15 Air Cleaner System - 4.0L EFI (Ranger/Bronco II)
AIR OUTLET
TUBES
TO THROTTLE IDLE BYPASS TO THROTILE BODY

BODY HOSE
~
~, ONLY A984o-0
75~~'
ONLY ....
... TOP VIEW
A9841C
Figure 16 Air Cleaner System - 4.9L through Figure 17 Air Cleaner System - 4.9Lthrough
7.5L E400 EFI (F-Series or 7.5L E400 EFI (E-Series)
Bronco)

ALL RIGHTS RESERVED
System Schematics
, FRESH AIR TUBE
HOT AIR TUBE
DUCT AND VALVE ASSY
BIMETAL
SENSOR
HEAT SHROUD /'
I
-~./
'I
~
1 I
+-1
I 1
1
1 I
1
CLEAN AIR TUBE
AIR CLEANER ASSY
THROTILE BODY A11622B
Figure 18 Air Cleaner System - 2.3L EFJ Dual Plug (49 States - Light Truck)

ALL RIGHTS RESERVED
System Diagnosis
1990 3.8L Supercharged Air Induction (Supercharger and Intercooler) System
NOTE: If the Air Induction System is functioning properly, return to Section 2 for further
driveability complaint diagnosis. .
1. Visually inspect all flange joints for indications of leaks.
2. Connect an EGO Sensor Monitor Box to read the rich/lean state of the EGO sensors.
3. Bring the engine to normal operating temperature.
I WARNING I
THE VEHICLE MUST BE IN A WELL VENTILATED AREA AWAY FROM ANY SOURCE OF
SPARK OR FLAME WHEN USING PROPANE.
4. With the engine idling in Neutral or Park and the parking brake engaged, spray small
amounts of propane around the following possible sources of air leaks:
Flange joint at the rear of the supercharger.
Bypass hose connections at the rear of the supercharger.
Flange joint at the supercharger outlet adapter.
4 tube joints at:
1) Supercharger outlet to the upper tube.
2) Upper intercooler inlet.
3) Lower intercooler outlet.
4) Intake manifold adapter inlet.
Intake manifold adapter to intake manifold flange.
5. When propane is sprayed near an induction system air leak, the EGO monitor box will
indicate "RICH" for one or two seconds, then return to normal switching. When the
propane is removed from the leak, the EGO monitor box will indicate "LEAN' after one
I
or two seconds.
6. If a leak is found, the entire system must be disassembled and the sealing surfaces
cleaned. Go to Shop Manual Fuel Group for disassembly.
NOTE: It is important that the intercooler tubes seal completely. Make sure there are no
foreign particles on the sealing surfaces of the tubes. The engine uses a "Mass
Air flow" system to calculate fuel flow. Any leak will cause poor operation and
performance. Use only Teflon Tape (ESE-M4G169-B) to seal the system.

ALL RIGHTS RESERVED
System Diagnosis
1990 112 1.9L EFI (Escort/Tracer) Air Intake System

NOTE: If the Air Intake System Is functioning properly, return to Section 2 for further
driveablllty complaint diagnosis.
1. Visually inspect that the air outlet tube is properly attached to the Mass Air Flow sensor
and the throttle body with the hose clamps.
2. Check that the Mass Air Flow sensor is properly attached to the cover with a gasket and
four screws.
3. Check the air inlet tube connection to the tray.
NOTE: Check for cracks in the tube and leaks In the entire system.
All Other Engine Systems:

NOTE: If the Air Intake System Is functioning properly, return to Section 2 for further
driveablllty complaint diagnosis.
CONDITION POSSIBLE SOURCE ACTION
Cranks normally but 1. Air filter restricted Go to Diagnostic Test [IM] .

slow to start.
Hesitates or stalls on 1- Vacuum motor inoperative Go to Diagnostic Test ~.
acceleration.
2. Air cleaner duct and valve door Go to Diagnostic Test ~ .
not operating properly
3. CWM inoperative Go to Diagnostic Test aAIJ .
4. Bimetal sensor inoperative Go to Diagnostic Test ~ .
Lack of power. 1. Vacuum motor inoperative Go to Diagnostic Test ~ .
2. Air cleaner duct and valve door Go to Diagnostic Test [IM] .
not operating properly
3. CWM inoperative Go to Diagnostic Test [00] .
4. Bimetal sensor inoperative Go to Diagnostic Test rIAl] .
5. Air filter element restricted Go to Diagnostic Test []A!] .
6. Collapsed air inlet and outlet Service or replace.
tubes
Poor fuel economy. 1. Air cleaner duct and valve door Go to Diagnostic Test ~ .
stuck in " hot air" position
2. CWM inoperative Go to Diagnostic Test [IAI] .
3. Bimetal sensor inoperative Go to. Diagnostic Test ~ .
4. Air filter element .restricted Go to Diagnostic Test [IM] .

ALL RIGHTS RESERVED
System Diagnosis
All Other Engine Systems (continued):
CONDITION POSSIBLE SOURCE ACTION
High oil consumption. 1. Air intake system sealing integrity Check hoses that connect the
air cleaner to the engine
(check for holes or cracks) and
ensure clamps are to proper
torque.
2. Air filter element sealing Check the air filter gasket
sealing area and the clean
side of the air cleaner housing
for excessive dirt. Replace
components as required.
Spark knocking. 1. Air cleaner duct and valve door Go to Diagnostic Test ~ .
stuck in hot air position
2. CWM inoperative Go to Diagnostic Test OATI .
3. Bimetal sensor inoperative Go to Diagnostic Test [I@ .
Air Induction Noise. 1. Loose air intake tube, outlet Connect or tighten screw(s) as
tubes, or air cleaner cover necessary.
2. Intake or outlet tube cracks or Service or replace.
holes
Engine Failure or 1. Unfiltered air from air outlet Connect or tighten screws.
Reduced Performance. tubes, air cleaner cover, idle by- Service as necessary.
pass hose or crankcase
ventilation hose

ALL RIGHTS RESERVED
System Diagnosis

NUMBER
Air Cleaner Cold Hold the Air Cleaner Cold Weather Modulator
Weather Modulator (9E862) in the closed palm of hand for about 15
minutes. Check chart below for leaks using a
vacuum pump at 54kPa (16 in-Hg) applied vacuum.
Place the Modulator in a container of ice water for
30 to 40 minutes. Check chart below for holding
vacuum using a vacuum pump at 54 kPa (16 in-Hg)
applied vacuum (Figure 1).
TO DUCT VALVE
VACUUM MOTOR
AS918-B
Figure 1 Cold Weather Modulator
COLOR TYPE HOLDS LEAKS

Black N/O Below - 6.7C (20F) Above 1.7C (35F)
Blue N/O Below 4.4C (40F) Above 12.8C (55F)
Green N/O Below 10C (50F) Above 24.4C (76F)
Yellow N/C Above 18.3C (65F) Below 10C (50F)

ALL RIGHTS RESERVED
System Diagnosis

NUMBER
IIA21 Air Cleaner Vacuum When'a vacuum of 27 kPa (8 in-Hg) or greater is

Motor . applied to the' vacuum motor, the door stem should
pull up and stay as long as vacuum is applied to
the vacuum motor (Figure 2).
_1110
l: ()
..... -II
I

A5921-8
Figure 2 Air Cleaner Vacuum Motor

ALL RIGHTS RESERVED
System Diagnosis
I
NUMBER
Air Cleaner Temperature Bring the temperature of the Air Cleaner

Sensor (Bimetal Sensor) Temperature Sensor (9E607) below 24C (75F) and
apply 27 kPa (8 in-Hg) of vacuum with a vacuum
pump at the vacuum source port of the sensor.
Does the duct door stay closed? If not, replace the
sensor (Figure 3).
BIMETAL SENSOR
VACUUM MOTOR
FRESH AIR
IN
Figure 3 Air Cleaner Temperature Sensor
The sensor will bleed off vacuum to allow the duct

door to open and let in fresh air at or above the
following temperatures:
Brown 24C (75F)

Pink, black or red 32.2C (gOF)
Blue, yellow or green 40.6C (105F)
f CAUTION!
Do not cool bimetal sensor while the engine is

running. If refrigerant R-12 is drawn into the intake
system while the engine is running, poisonous
phosgene gas will be exhausted into the test area.
Perform this test only in a well-ventilated area.

ALL RIGHTS RESERVED
System Diagnosis

NUMBER
Air Cleaner Filter Remove the Air Cleaner Filter Element from the Air
Element Cleaner Assembly. Inspect for heavy contamination.
If the filter cannot be cleaned by shaking and
applying vacuum, replace the filter element.
Air Cleaner Duct and If the duct door is in the closed to fresh air
Valve System position, remove the hose from the Air Cleaner
Vacuum Motor. The door should go to the open to
fresh air position. If it sticks or binds, service or
If the door is in the open to fresh air position,
check the door by applying vacuum of 27 kPa
(8 in-Hg) or greater to the Air Cleaner Vacuum
Motor. The door should move freely to the closed
to fresh air position. If it binds or sticks, service or
NOTE: Make sure the Vacuum Motor is functional
before changing the Duct and Valve
System.
VACUUM MOTOR
FRESHAIR
IN
~-~)
~ FRESH AIR OPEN
/)
FULL HEAT
~r-_--_~
HEATED
AIR IN
~- FRESH AIR CLOSED
A12761A

ALL RIGHTS RESERVED
SECTION 9
Positive Crankcase
Ventilation (PCV) Systems
Contents
Diagnostics - Typical PCV System (All except 1.9L CFI) 9-2
Diagnostics - 1.9L CFI PCV System 9-4

ALL RIGHTS RESERVED
Positive Crankcase Ventilation (PCV) Systems 91
System "Description
TYPICAL POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM
The Positive Crankcase Ventilation (PCV) system (Figure 1) cycles crankcase gases back
through the engine where they are burned. In a typical system, the PCV valve regulates the
amount of ventilating air and blow-by gas to the intake manifold and prevents backfire from
traveling into the crankcase. The PCV valve should be mounted in a vertical position (Figure
1). On some engine applications, the PCV system is connected with the evaporative emission
system.
1.9L CFI Positive Crankcase Ventilation (PCV) System
The Positive Crankcase Ventilation (PCV) vent system for the 1.9L CFI engine (Figure 2) does
not depend on a flow of scavenging air, as do all other Ford engines, but evacuates
crankcase vapors that are drawn into the intake manifold in metered amounts through a Dual
Orifice Valve Assembly. A small orifice is connected to the intake manifold at all times. A
larger orifice, controlled by a throttle body port signal, opens to the intake manifold during part
throttle and WOT operation. If the availability of crankcase vapor is low (at idle for instance),
air may be drawn along with crankcase vapor through the smaller orifice. If the availability of
crankcase vapor is high (at high-speed operation) crankcase vapor is delivered to the intake
manifold through both orifices. If the amount of crankcase vapor available exceeds that which
can be handled by the two orifices, the excess flow is routed to the air cleaner. The Dual
Orifice Valve is the critical point of this system.

ALL RIGHTS RESERVED
9-2 Positive Crankcase Ventilation (PCV) Systems
Positive Crankcase Diagnostic

PCV
Ventilation (PCV) System Test
DIAGNOSTICS - TYPICAL PCV SYSTEM (ALL EXCEPT 1.9L CFI)
REMOTE AIR
CLEANER OR
AIR OUTlET
TUBE
Figure 1 Typical PCV System (Except 1.9L with CFI)

Set parking brake and block wheels. Place transmission/transaxle in NEUTRAL or PARK.
Place the A/C-Heat selector in the OFF position. Go to PCV Test Step 1.
TEST STEP RESULT ACTION TO TAKE
PCV1 STUCK PCV VALVE CHECK
Remove PCV valve from rocker cover grommet. Yes ~ REINSTALL PCV valve.
GO to IpCV21.
Shake the PCV valve.
Does the PCV valve rattle when shaken? No PCV valve is sticking.
REPLACE PCV valve.
PCV2 PCV SYSTEM CHECK
Start engine and bring to normal operating Yes ~ System is OK.

temperature. RECONNECT hose.
GO to Section 2 for
For 2.3L HSC, 2.5L, 2.9L TRK and 4.9L: other possible causes
Remove the corrugated hose from the oil of vehicle symptoms.
separator nipple.
No ~ System is plugged or
Place a stiff piece of paper over the nipple end.
Evaporative Emission
Wait one minute. Valve is leaking (if
For all others: ~ed). GO to
~.
Disconnect hose from remote air cleaner or air
outlet tube (tube connecting mass air meter and
throttle body).
Place a stiff piece of paper over the hose end.
Wait one minute.
Does the vacuum hold the paper In place?

ALL RIGHTS RESERVED
Positive Crankcase Ventilation (PCV) Systems 9..3
Positive Crankcase' Diagnostic

PCV.
Ventilation (PCV) System ~ Test
.
-
pcv31 EVAPORATIVE EMISSION SYSTEM CHECK
Disconnect evaporative hose (if equipped), cap the

connector, and retest.
Yes . GO to Evaporative
Emission System,
Section 7.
Place a stiff piece of paper over the hose/nipple,
as in PCV2 . Wait one minute. No ~ CHECK for vacuum
leaks/obstruction in the
Does the vacuum hold the paper In p.lace,,? .. system: oil cap, PCV
~
valve, hoses, cut
grommets (oil separator
on 2.3L, HSC, 2.5L,
2.9L TRK and 4.9L)
and rocker cover for
bolt torque/gasket leak.
, SERVICE as necessary.
~,
.'
.. -
.-
"

ALL RIGHTS RESERVED
9-4 Positive Crankcase Ventilation (PCV) Systems

PCV
DIAGNOSTICS - 1.9L CFI PCV SYSTEM
CRANKCASE
VENT
CONNECTOR
'"
FRONTOF~E
TO THROTTLE
BODY PORT
A11550-A
Figure 2 1.9L CFI Engine PCV System

Set parking brake and block wheels. Place transmisslon/transaxle In NEUTRAL or PARK.
Place the A/C-Heat selector In the OFF position. Bring engine to normal operating
temperature and GO to PCV Test Step 1'.
PCV1 1.9L CFI HIGH-SPEED PCV CHECK
Remove vacuum control hose at the dual orifice Yes ~ High-speed PCV
valve assembly (located at the throttle body port). Isyste, is OK. GO to
PCV2 .
Apply manifold vacuum to port.
Is there significant change In engine rpm? No ~ REPLACE the dual
orifice valve assembly.

ALL RIGHTS RESERVED
Positive Crankcase Ventilation (PCV) Systems 9-5

PCV
pcv211.9L CFI LOW-SPEED CHECK
Remove crankcase vent connector from side of Yes ~ Low-speed PCV system
air cleaner. is OK. GO to Section
Place a stiff piece of paper over crankcase vent 2 for other possible
connector nipple. Wait for one minute. causes of vehicle
symptoms.
Does vacuum hold paper in place?
No ~ GO to Ipcval.
PCV31 CRANKCASE VENT CONNECTOR
CHECK
Remove vacuum hose (small port) at crankcase Yes ~ REPLACE crankcase

vent connector. vent connector.
Place a stiff piece of paper over vacuum hose.
Does vacuum hold the paper in place? No ~ GO to IpCV41.
PCV41 DUAL ORIFICE VALVE ASSEMBLY
CHECK
Remove dual orifice valve assembly from system. Yes ~ GO to Section 2 for
Check for blockage through valve. other possible causes
of vehicle symptoms.
Is valve clear of blockage?
No ~ REPLACE dual orifice

valve assembly.

ALL RIGHTS RESERVED
SECTION 10
Thermactor Systems
(Secondary Air Injection)
Contents
System Descriptions 10-1
Thermactor Air Injection System 10-1
Managed Air Thermactor System 10-5
Pulse Air System (Thermactor II) 10-11
Functional Diagnosis ; 10-18
Thermactor Air Pump Drive Belt Adjustment 10-18
Air Supply Pump 10-19
Air Silencer/Filter (Air Pump and Pulse Air .Inlet) 10-20
Air Bypass Valves 10-21
Air Check Valve 10-23
Air Supply Control Valve 10-24
Air Control Valve (Switch-Relief) 10-25
Air Pump Resonator 10-27
Combination Air Bypass/Air Control Valve 10-28
Dual Thermactor Air Control Solenoid Valve 10-30
Solenoid Vacuum Valve Assembly 10-31
Thermactor Idle Vacuum Valve 10-32
Vacuum Control Valve 10-33
Vacuum Check Valve 10-35
Vacuum Reservoir 10-36
Pulse Air Valve 10-37

ALL RIGHTS RESERVED
Thermactor Systems (Secondary Air Injection) 10-1
System Descriptions
THERMACTOR AIR INJECTION SYSTEM
The Thermactor (air injection) Exhaust Emission Control System reduces the hydrocarbon and
carbon monoxide content of exhaust gases by continuing the combustion of unburned gases
after they leave the combustion chamber by injecting fresh air into the hot exhaust stream
leaving the exhaust ports or into the catalyst. At this point, the fresh air mix~s with hot
exhaust gases to promote further oxidation of both the hydrocarbons and carbon monoxide,
thereby reducing their concentration and converting some of them into harmless carbon dioxide
and water. .
During some modes of operation (Hwy Cruise/WOT), the thermactor air is dumped to
atmosphere to prevent overhea~ing in the. exhaust system.
A typical Air Injection System consists of:
Air Supply Pump and Centrifugal Filter or Remote 'Filter
Air Bypass Valve
Check Valves
Air Manifold
Air Hoses
Air Control Valve

ALL RIGHTS RESERVED
Thermactor Systems (Secondary Air Injection)
System Descriptions
AIR CONTROL
VALVE
CHECK VALVES
'"FRONT OF ENGINE
~
"'- ~
FRONT OF ENGINE
A11619-A
Figure 1 7.5L FI Thermactor System - F-Series with 400

ALL RIGHTS RESERVED
System Descriptions
VALVE ASSY AIR SUPPLY CONTROL
AIR BYPASS HOSE

OUTLET
AIR PUMP--......;;;;;~~
A11618-A
Figure 2 Dual Ou~/et Air Pump System - 7.5L EFI All GVW Auto/Manual Except F-Series with
E40D

ALL RIGHTS RESERVED
104 Thermactor Systems (Secondary Air Injection)
System Descriptions
FRONT OF
ENGINE
A12773A
Figure 3 Dual Air Pump System - 6.1L/7.0L Engines

ALL RIGHTS RESERVED
System Descriptions
MANAGED AIR THERMACTOR SYSTEM
The Managed Air Thermactor System (Figure 4) is utilized in electronic control systems to
divert thermactor air either upstream to the exhaust manifold check valve or downstream to
the rear section check valve and dual bed catalyst. The system will also dump thermactor ir
to atmosphere during some operating modes.
An air control valve (9F491) is used to direct the air either upstream or downstream. An air
bypass valve (98289) is used to dump .air to atmosphere (Figure 4). .
~xamples of other Managed Air Thermactor Systems are shown in Figures 5, 6, 7, 8, 9, 10,
11, 12 and 13.
AIR PUMP
CONTROL
VACUUM
AIR CONTROL
VALVE-9F491
EXHAUST
MANIFOLD
DUAL CATALYTIC CONVERTER
AS9800F
Figure 4 Typical Managed- ~ir. Thermact~r System

ALL RIGHTS RESERVED
10-6 Thermactor Systems (Secondary Air Injection)
System 'Descriptions
VALVE ASSY
CHECK
VALVE
" FRONT OF
ENG.",
VALVE ASSY
FRONT OF ENGINE
AIR
PUMP
An...!
Figure 5 Locations of Thermactor Valves - 5.0L Mustang/Mark VII
COMBINATION AIR BYPASS

CONTROL VALVE
"""- FRONT OF
ENGINE
CHECK
VALVES
I - . _ - - - A I R PUMP
A12774-A
Figure 6 Locations of Thermactor Valves - 5.0L Lincoln Town Car, and Ford Crown Victoria/
Mercury Grand Marquis

ALL RIGHTS RESERVED
System Descriptions
~*-~--CHECK VALVE
CHECK VALVE - - -.......~~
AIR CONTROL
'\""~~~--VALVE (DUMP)
AIR PUMP INLET

SILENCER/FILTER ----e.~
FRONT OF
ENGINE PUMP ASSY
~
1 -
A9393C
Figure 7 5.8L EFI 0/8500 GVW F-Series
PUMP ASSY
A9394-B
Figure 8 5.8L EFI UI8500 GVW F-Series/Bronco

ALL RIGHTS RESERVED
System Descriptions
AIR BYPASS
VALVE
A9395-B
Figure 9 5.8L EFI UI8500 GVW E-Series
PUMP ASSY
A9396-B
Figure 10 5.8L EFI 018500 GVW E-Series

ALL RIGHTS RESERVED
Thermactor Systems (Secondary Air Injection) 10..9
System Descriptions
,:::y~ AIR CONTROL

VALVE
CHECK
CHECK~_~~~
VALVE
VALVE
~ONTOF'
ENGINE
FRONT VIEW A12775-A
Figure 11 5.0L F-Series and Bronco

ALL RIGHTS RESERVED
10-10 Thermactor Systems (Secondary Air InJection)
System Descriptions
CHECK VALVE
FRONT OF ENGINE
A13526A
Figure 12 4.9L AIT 018500 GVW and MIT

ALL RIGHTS RESERVED
Thermactor Systems (Secondary Air Injection) 1011
System Descriptions
AIR BYPASS
VALVE
'"
CHECK
VALVE FRONT OF
ENGINE
'"
AIR PUMP
A13527-A
Figure 13 4.9L AfT Uf8500 GVW

ALL RIGHTS RESERVED
1012 Thermactor Systems (Secondary Air InJection)
1 ,_S_y_s_te_m
__D_e_s_c_r_iP_t_io_D_S _
PULSE AIR SYSTEM (THERMACTOR II)
Some engines are equipped with an air injection system called Pulse Air or Thermactor II. The
system does not use an air pump. The system uses natural pulses present in the exhaust
system to pull air into the catalyst through pulse air valves. The pulse air valve is connected
to the catalyst with a long tube and to the air cleaner and silencer with hoses.
/
FRONT OF ENGINE
/'
A11617A
Figure 14 1.9L EFI HO Escort-(50 States)

ALL RIGHTS RESERVED
1 S_y_st_e_m
__D_e_s_c_ri_p_t_iO_D_S __
FRONT OF
VEHICLE
"'" DUAL CHECK

VALVE
A13528-A
Figure 15 2.5L Taurus

ALL RIGHTS RESERVED
System Descriptions
CONTROL VALVE
(ON CALIFORNIA VEHICLES ONLY)
~FRONT OF
ENGINE
A13529A
Figure 16 2.3L Tempo/Topaz

ALL RIGHTS RESERVED
SYMPTOM POSSIBLE. SOURCE ACTION

Backfire (Exhaust) Air bypass valve malfunction Perform bypass valve diagnosis
Air control valve malfunction Perform air control valve diagnosis
Combination air bypass/control Perform combination valve
valve malfunction diagnosis
Thermactor solenoid valve Perform solenoid diagnosis
malfunction
Thermactor idle vacuum valve Perform TIV diagnosis
malfunction
Exhaust manifolds or pipes loose Inspect and tighten nuts or bolts to
specification.
Surge at Steady Speed Air control valve malfunction Perform control valve diagnosis
Combination air bypass!control Perform combination valve
Thermactor solenoid malfunction Perform solenoid diagnosis
Engine Noise - (Hiss) Thermactor hose leaks or Visual inspection of hoses and
disconnect connections
Engine Noise - Thermactor hose or valves leak Visual inspection of hoses and
(Rap, Roar) exhaust valves. Perform air check valve
diagnosis
Poor Fuel Economy Air control valve malfunction Perform air control valve diagnosis
Combination air bypass/control' Perform combination valve
malfunction
Disconnected vacuum or electrical Visual inspection
connections for thermactor
components
Exhaust Smoke (White) Disconnected vacuum or electrical Visual inspection
components
Air bypass valve malfunction Perform bypass valve diagnosis
Combination air bypass/control
valve malfunction
.
Perform combination valve
diagnosis
malfunction
State Emission Test Failure Disconnected vacuum or electrical Visual inspection
components
malfunction
Rolling Idle Thermactor solenoid valve Perform solenoid diagnosis
,',malfunction
Disconnected vacuum or electrical Visual inspection
components

ALL RIGHTS RESERVED
THERMACTOR SYSTEM NOISE TEST

J CAUTION 1
Do not use a pry bar to move the air pump for belt adjustment.
NOTE: The thermactor system is not completely noiseless. Under normal conditions,
noise rises In pitch as engine speed Increases. To determine if noise is the fault
of the air Injection system, disconnect the belt drive (only after verifying that
belt tension Is correct), and operate the engine. If the noise disappears, proceed
with the following diagnosis.
Diagnosis

Excessive Belt Noise Loose belt. Tighten to specification using Tool
T75L-9480-A or equivalent to hold
belt tension and Belt Tension
Gauge T63L-8620-A or equivalent.
CAUTION: Do not use a pry bar
to move air pump.
,
Seized pump. Replace pump.
Loose pulley. Replace pulley and/or pump if
damaged. Tighten bolts to 13.6-
17.0 Nm (120-150 Ib-in).
Loose or broken mounting Replace parts as required and
brackets or bolts. tighten bolts to specification.
Excessive Mechanical Noise, Overtightened mounting bolt. Tighten to 34 Nm (25 Ib-ft).
Chirps, Squeaks, Clicks or Ticks
Overtightened drive belt. Same as loose belt.
. Excessive flash on the air pump
adjusting arm boss.
Remove flash from the boss.
Distorted adjusting arm. Replace adjusting arm.

Pump or pulley mounting Tighten fasteners to specifications.
fasteners loose.

ALL RIGHTS RESERVED
,I Diagnosis By Symptom
-----------------------------------------------
Excessive Thermactor System Leak in hose. Locate source of leak usi~g soap
Noise (Putt-Putt, Whirling or solution and replace hoses as
Hissing) necessary;
Loose, pinched o~ kinked hose. Reassemble, straighten or replace
hose and clamps as required.
Hose tou~hing other engine parts. Adjust hose to prevent contact with
other engine parts.
Bypass valve inoperative.. Test the valve.
Check valve inoperative. Test the valve.
Restricted or bent pump outlet Inspect fitting and remove any .
fitting. flash blocking the air passage way.
Replace bent fittings.
Air dumping through bypass valve On many vehicles, the thermactor
(at idle only). system has been designed to dump
air at idle to prevent overheating
the catalyst. This condition is
normal. Determine that the noise
persists at higher speeds before
proceeding.
Air dump through bypass. valve On many vehicles, the thermactor
(decel and cruise). air is dumped in the air cleaner or
in remote silencer. Make sure
hoses are connected and not
cracked.
Air pump resonator leaking or Check resonator for hole or
blocked. restricted inlet!outlet tubes.
Excessive Pump Noise (Chirps, Worn or damaged pump. Check the thermactor system for
Squeaks and Ticks) wear or damage and make
necessary corrections.
Engine noise-CRap or Roar) Hose disconnected. Audible and visual inspection to

assure all hoses are connected.
State Emissions Test Failure Restricted hose. Inspect hoses for crimped and/or
kinked hoses.
Plugged pulse air silencer. Remove inlet hose and inspect

silencer inlet for dirt and foreign
material. Clean or replace silencer
as appropriate.
Pulse air valve malfunction, leaking Perform pulse air check valve
or restricted. diagnosis.
Pulse air control valve malfunction. Perform pulse air control valve
diagnosis.

ALL RIGHTS RESERVED
.1 Functional Diagnosis
THERMACTOR AIR PUMP DRIVE BELT ADJUSTMENT
On most applications. drive belt adjustment ,for the Air Pump is accomplished by adjusting
other component position (example-idler and alternator). For those applications that utilize an
automatic tensioner. no adjustment is necessary. For those applications requiring Air Pump
movement to adjust belt tension, procede with the following:
1. Check all air pump pulleys and mounting bolts, and tighten to specification. if required.
2. Install the belt tension gauge (Tool T63L-8620-A or equivalent) on the drive belt, and
check the tension. Compare the belt tension to the specified belt tension and adjust as
necessary.
3. If adjustment is necessary, loosen the air pump mounting and adjusting arm bolts. move
the air pump toward or away from the engine until the correct tension is obtained. Use air
pump belt tensioning tool (Tool T75L-9480-A or equivalent) to hold belt tension while
tightening the mounting bolts. Install the tension gauge and check the belt tension.
r. CAU!~~N:I
Do not use a pry bar.

ALL RIGHTS RESERVED
Thermactor Systems (Secondary Air InJection) 10-19
Functional Diagnosis: 9A486 I r - - - - - - - -
Air Supply Pump
DESCRIPTION
The Air Supply Pump is a belt-driven, positive displacement, vane-type pump that provides air
for the Thermactor system. It is available in 19 and 22 cubic inch sizes, either of which may
be driven with different pulley ratios for different applications. Pumps receive air from a remote
silencer filter on the rear side of the engine air cleaner attached to the pumps' air inlet nipple
or through' an impellor-type centrifugal filter fan.
AEAACOVER
IMPELLER AIR INLET

A5H3-C
Figure 17 19 Cubic Inch Thermactor Air Figure 18 19 and 22 Cubic Inch Thermactor
Supply Pump - Car Air Supply Pump - Trucks
Functional Check
1. Check belt tension and adjust to specification.
2. Disconnect air supply hose from bypass control valve.
3. The pump is operating satisfactorily if airflow is felt at the pump outlet and the flow
increases as the engine speed is increased.
[ ~~~!ION]
Do not pry on the pump to adjust belt. The aluminum housing 18 likely to collapse. see
Air Pump Drive Belt Adjustment.

ALL RIGHTS RESERVED
1020 Thermactor Systems (Secondary Air InJection)
Funcstilonal D/FiagnOSiS:
Aior i encer ilter
9G427
9H467
I n
LIT
~(=--Ai_r_P_u_m-=-p_a_n_d_P_u_ls_e_A_ir_I_n_le_t~) -'--- --' L..-_ _ ...;..S'~LN _
DESCRIPTION
The Air Silencer is a combustion silencer and filter for air supply pumps that are not equipped with an
impeller-type centrifugal air filter fan or for Pulse Air (Thermactor II) systems. The air silencer is
mounted in.a convenient position -in the engine compartment and is connected to the air supply pump
or pulse air valve inlet by means of a flexible hose.
TO
PUMP
NOTE: ON HEAVY~~~
DUTY TRUCKS.
APPROXIIIATELY
THREE TillES TO PULSE AIR
THIS SIZE. VALVE OR DUAL AIR PUMP A6979-C
Figure 19 Air Silencer - 9H467, Typical Figure 20 Air Silencer - 9G427, Typical
Functional Check
1. Inspect hoses and air silencer for leaks.
2. Disconnect hose from air silencer outlet, remove silencer and visually inspect for plugging.
3. The air silencer is operating satisfactorily if no plugging or leaks ar~ encountered.

ALL RIGHTS RESERVED
F~nctional Diagno~is:
98289
Air Bypass Valves
DESCRIPTION
There are two general groups of Air Bypass Valves, normally closed and normally open.
Normally closed valves supply air to the exhaust system with medium and high applied
vacuum $ignals during normal (engine at normal operating temperature) modes. With low or no
vacuum applied, the pumped air is dumped through the silencer ports of the valve or through
the dump port.
VACUUM
,-p...._ - NIPPLE
OUTLET
OUTLET
INLET
INLET
AIR BYPASS/RELIEF
/
EXHAUST PORT
CONNECTION FOR
REMOTE DUMP
A8002~E
Figure 21 Normally Closed Air Bypass Valves
Normally Closed. Bypass Valves (9B289)
Functional Check
1. Disconnect the air supply hose at the valve outlet.
2. Remove vacuum line to check to see that a vacuum signal is present at the vacuum
nipple. There must be a vacuum present at the nipple before proceeding.
3. With the engine at 1500 rpm and the vacuum line connected to the vacuum nipple, air
pump supply air should be heard and felt at the air bypass valve outlet (Figure 21).
4. With the engine at 1500 rpm, disconnect the vacuum line. Air at the outlet should be
significantly decreased or shut off. Air pump supply air should be heard or felt at the
silencer ports, or at the dump port.
5. If the normally closed air bypass valve does not successfully complete the above tests,
check the air pump. If the air pump is operating satisfactorily, replace the air bypass
valve.

ALL RIGHTS RESERVED
10-22 Thermactor Systems- (Secondary Air InJection)
Functional Diagnosis:
98289'
Air Bypass Valves
Normally Open Air Bypass Valves without Vacuum Vent
Heavy Truck Applications
Normally Open Valves without a Vacuum Vent provide a timed dump of air for two seconds
nominal when a sudden high vacuum of about 68 kPa (20 in-Hg) is applied to the signal port.
This prevents backfire during deceleration. .
AIR BYPAss/RELIEF
EXHAUST PORTS
ELBOW
OUTLET
A8357-A
Figure 22 Normally Open Without Vacuum

Vent
Functional Check
1. Disconnect the air supply line at the valve outlet (Figure 22).
2. Carefully disconnect the vacuum line at the vacuum nipple.

r CAU'I~N !
The vacuum port may break If care Is not taken.
3. With' the engine at 1500 rpm, air should be heard and felt at the valve outlet.
4. Connect a direct vacuum line that is free from restrictions from any manifold vacuum
source to the vacuum nipple on the air bypass valve. Air at the outlet should be
momentarily decreased or shut off.
5. Air pump supply air should be heard or felt at silencer ports (Figure 22) during the
momentary dump. Restore all original connections. If any of the above tests are not
satisfactorily completed, check the air pump. If the air pump is operating satisfactorily,
replace the air bypass valve.

ALL RIGHTS RESERVED
Thermactor'Systems (Secondary Air Injection) 1023
Functional Diagnosis:. I----O-NL-ET-.---

L.;",.A_i_r.....C_h_e_ck_v_a_lv_e ....L.-_9A_48_7-.1. ,
DESCRIPTION
The Air Check Valve (Figure 23) is a one-way valve that allows thermactor air to pass into the
exhaust system while preventing exhaust gases from passing in the opposite direction.
FREE

FLOW
OUT TO
EXHAUST
MANIFOLD AND ""'-11. . . .- ....
OR CATALYTIC
CONVERTER------.- A5961E
Figure 23 Air Check Valve
Functional Check
Visually inspect the thermactor system hoses, tubes, control valve(s) and check valve(s) for
leaks that may be due to backflow of exhaust gas. If holes are found and/or traces of
exhaust gas products are evident, the check valve may be suspect.
As shown in the above illustrations, the valves should allow free flow of air in the direction
of the arrow only. The valve(s) should check (or block) the free flow of exhaust gas in the
opposite direction.
Replace the valve if air does not flow as indicated or if exhaust gas backflows opposite of
the direction of the arrow.

ALL RIGHTS RESERVED
Functional Diagnosis: Ir-----~------:

Air SUPl!ly 9F491
,,-C_o_n_t_ro_~I_V_~al_v_e -.&.- --, ACV
DESCRIPTION
The Air Supply Control Valve (Figure 24) is used in the Thermactor (Secondary Air) System.
The Air Control Valve directs air pump output to the exhaust manifold or downstream to the
catalyst system depending upon the engine control strategy. It may also be used to dump air
to the air cleaner or dump silencer.
A698H)
Figure 24 Air Control Valve
Functional Check
1. Verify that airflow is being supplied to the valve inlet by disconnecting the air supply hose
at the inlet and verifying the presence of airflow with the engine at 1500 rpm. Reconnect
the air supply hose to the valve inlet.
2. Disconnect the air supply hose at outlets A and B (Figure 24).
3. Remove the vacuum line at the vacuum nipple.
4. Accelerate the engine to 1500 rpm. Airflow should be heard and felt at outlet B with little
or no airflow at outlet A (Figure 24).
5. With the engine at 1500 rpm, connect a direct vacuum line from any manifold vacuum
fitting to the air control valve vacuum nipple. Airflow should be heard and felt at outlet A
with little or no airflow at outlet B.
6. If airflow is noted in Steps 4 and 5, valve is O.K. Reinstall clamps and hoses and return
to Diagnosis By Symptom or Diagnostic Routines.
7. If valve does not pass Step 4 and/or 5, replace valve.

ALL RIGHTS RESERVED
Air Control Valve

F_U_D_c_ti_o_n_a_1_D_i_ag_n_O_s_iS_:
___(Switch-Relief)
-a...-_~~~9_1___"" I:--'--~-:
----
DESCRIPTION
The Air Supply Control Valve is used in the Th.ermactor (Secondary Air) System.
The Air Control Valve directs air pump output to the exhaust manifold or downstream to the
catalyst system depending upon the engine control strategy. The air control valve may be
used as a Thermactor bypass valve (Figure 26), directing air to the catalyst!exhaust system or
to a remote air dump location depending on engine control strategy. A pressure relief valve
also provides air pump protection in the event of excessive exhaust back pressure or system
blockage.
Figure 25 Air Control Valve (Switch-Relief)
OUTLET B
Figure 26 Air Control Valve (Thermactor Bypass Type)

ALL RIGHTS RESERVED
Functional Diagnosis: I---~-----'

.l.-Ai__r_c_o_n_t_ro_l_v_a_l~v_e
JSwitch-Relief) 9_F_4_9_1--" , :
Functional Check
1. Verify that airflow is being supplied to the valve inlet by disconnecting the air supply hose
at the inlet and verifying the presence of airflow with the engine at 1500 rpm. Reconnect
the air supply hose to the valve inlet.
2. Carefully disconnect the air supply hoses at outlets A and B (Figure 25 or Figure 26).
3. Carefully remove the vacuum line at the vacuum nipple.

i CAUTION 1
The vacuum port may break if care is not taken.
4. Accelerate the engine to 1500 rpm. Airflow should be heard and felt at outlet B with little
or no airflow at outlet A (Figure 25 or Figure 26).
5. With the engine at 1500 rpm, connect a direct vacuum line from any manifold vacuum
fitting to the air control valve vacuum nipple. Airflow should be heard and felt at outlet A
with little or no airflow at outlet B.
6. Restore all connections. If conditions above are not met. replace the air control valve.

ALL RIGHTS RESERVED
9
L..-F_U_D_c_t_iO_D_a_I_"_D_i_a__D_O_Si_S_: '1-.- - - - - - . . . . . ,
_Air Pump Resonator .
DESCRIPTION
The Air Pump Resonator (Figure 27) reduces air dump noise during cold start and some cruise
modes..
-
INLET oJ'
A13530-A
Figure 27 Air Pump Resonator
Functional Check
1. Visually inspect for holes.
2. Remove hoses and check for blocked/restricted ports.
3. Replace Resonator if part has holes or ports are blocked/restricted.
4. Reconnect hoses, install clamps, and tighten to specification.

ALL RIGHTS RESERVED
TITLE
Combination Air
BASIC PART NO.
9F491
Ir-----'------...,
SYMBOL
Lo-B--.;;.yp~a_ss_/_A_ir_C_o_n_tr_o_I_V_a_lv_e ~ ACV
DESCRIPTION
The Combination Air Control/Bypass Valve (Figure 28) combines the secondary air bypass and
air control functions. The valve is located in the air supply line between the air pump and the
upstream/downstream air supply check valves.
The air bypass portion controls the flow of thermactor air to the exhaust system (air control
portion of the valve) or allows thermactor air to be bypassed to atmosphere. When air is not
being bypassed, the air control portion of the valve switches the air injection point to either an
upstream or downstream location.
INLET FROM VACUUM PORT "S"

AIR PUMP AIR CONTROL
VACUUM PORT
"0" AIR BYPASS
A13531A
Figure 28 Combination Air Bypass/Air Control

Valve
Functional Check
Normally closed, Figures 28 and 29.
1. Disconnect hoses from outlets A and B.
2. Disconnect and plug vacuum line to port D.
3. With engine operating at 1500 rpm, airflow should be noted coming out of the bypass
vents.
4. Reconnect vacuum line to port 0, and disconnect and plug vacuum line to port S. Ensure
vacuum is present in the line to vacuum port D.
5. With engine operating at 1500 rpm, airflow should be noted coming out of outlet B (no
airflow should be detected at outlet A).

ALL RIGHTS RESERVED
Combination Air 9F491
Bypass/Air Control Valve
- VALVE POPPET POSITION

WITHOUT VACUUM SIGNAL
- + - + - - - - A I R FROM
AIR PUMP
VALVE POPPET POSITION

WITHOUT VACUUM SIGNAL
OUTLET A IJ=~~ VACUUM

-i PORT S
TO ENGINE OR
CATALYST AIR CONTROL
DIAPHRAGM
SEAT FOR OUTLET A IS AVAILABLE

IN BLEEDS OF:
5 PERCENT - BLUE
10 PERCENT - RED
20 PERCENT - GREEN
SEAT FOR OUTLET B HAS 5
OUTLET B PERCENT, 10 PERCENT OR
TO ENGINE OR 20 PERCENT OF BLEED
CATALYST MOULDED INTO BODY A6835-D
Figure 29 Valve Assembly Exhaust Air Supply Control (Normally Closed) with Bleed
6. Apply 27-34 kPa (8-10 in-Hg) vacuum to port S. With engine operating at 1500 rpm,
ai'"!low shou.ld be noted coming out of outlet A.
7. If the valve is the bleed type, some lesser amount of air will flow from outlet A or 8, and
the main dis~harge will change when vacuum is applied to port S.

ALL RIGHTS RESERVED
Dual Thennactor 9H465
I ~
n
. .A. i_r_C_o_n_t_r_o_I_S_o_l_e_n_o_i_d_V_a_lv_e_----..I. ---' . . . SO_lv _
DESCRIPTION
The Dual Thermactor Air Control Solenoid Valve (Figure 30) assembly consists of two normally
closed solenoid vacuum valves (TAB and TAD), one controlling the thermactor air bypass valve
and the other the thermactor diverter valve. Both are vented when de-energized, sourced by
the intake manifold vacuum reservoir and controlled by an EEC system (they are also
discussed in the EEC and MCU Systems diagnostic procedures). Also used on 2 wheel drive/4
wheel drive vehicles and single solenoids for EGR shutoff.
E8AE9H465-8A
Figure 30 Dual Thermactor Air Control Solenoid Valve

DIAGNOSIS
For diagnostics, refer to the EEC-IV Quick Test, Section 14.
The function of each valve can be determined by externally energizing with vacuum sourced
and output gauged. (Refer to Solenoid Vacuum Valve, NC).
The resistance of each solenoid should be between 51 and 108 ohms when checked at the
coil terminals. If the resistance is not within these values, the solenoid should be replaced.
NOTE: The valves can be expected to have a very small leakage rate when energized or
de-energized. This leakage is not measurable In the field and Is not detrimental
to valve function.
Thermactor Air Strategy

Thermactor Air States TAB Solenoid TAD Solenoid
Upstream On On
Downstream On Off
Bypass Off Off
TAB - Thermactor Air Bypass
TAD - Thermactor Air Diverter

ALL RIGHTS RESERVED
Solenoid Vacuum
Valve Assembly
9D474
I JJ-+
SOL V
1 . . . . . - - - _
DESCRIPTION
Normally Closed
The Normally Closed Solenoid Valve Assembly (Figure 31) consists of two vacuum ports with
an atmospheric vent. The valve assembly can be with or without control bleed. The outlet port
of the valve is opened to atmospheric vent and' closed to the inlet port when de-energized.
When energized, the outlet port is opened to the inlet port and closed to atmospheric vent.
The control bleed is provided to prevent contamination entering the solenoid valve assembly
from intake manifold.
ATMOSPHERIC VENT
BLADE TYPE
TERMINALS OR MOLDED-----.
CONNECTOR
INLET PORT
A6847-8
Figure 31 Typical Solenoid Valve

Assembly - Normally Closed
DIAGNOSIS
The ports should flow air when the solenoid is energized.
The solenoid resistance when checked at the terminals should be between 51 and 108 ohms.
If the solenoid resistance is not within these values, the solenoid should be replaced.
Refer to the EEC-IV Quick Test, Section 14.
NOTE: The valve can be expected to have a very small leakage rate when energized or
de-energized. This leakage is not measurable in the field and Is not detrimental
to valve function.

ALL RIGHTS RESERVED
TITLE
Thermactor Idle
BASIC PART NO.
9G328
SYMBOL
I a
~
'--V_a_cu_u_m_V_a_l_v_e ---'- ... ~ IV_V ---'
DESCRIPTION
The TIV Valve (Figure 32) vents the vacuum signal to the atmosphere when the preset
manifold vacuum or pressure is exceeded. It is used to divert Thermactor airflow during cold
starts to control exhaust backfire.
\
SMALL NIPPLE - APPLY
MANIFOLD VACUUM
AT IDLE IN NEUTRAL
ATMOSPHERIC
VENT HOLES
A5968C
Figure 32 Thermacfor Idle Vacuum Valve
Functional Checks
TIV Valves with code words ASH or RED on decal:
1. With the engine at idle, in NEUTRAL, apply vacuum to small nipple and place fingers over
the TIV Valve atmospheric vent holes (Figure 1). If no vacuum is sensed, the TIV is
damaged and must be replaced.
2. While the engine is still idling in NEUTRAL, apply vacuum shown below, to the TIV Valve
large nipple from a test source. If vacuum is still sensed when placing fingers over vent
holes, the TIV is damaged and must be replaced.
3. If TIV meets both requirements, disconnect the TIV small nipple from manifold vacuum
and the TIV large nipple from the test vacuum. Reconnect the TIV valve to original hoses
or connectors.
TIV Decal Code Mode Vacuum kPa (In. Hg.)

Ash 5.1 (1.5) - 10 (3.0)
Red 11.8 (3.5) - 15.2 (4.5)

ALL RIGHTS RESERVED
Functional Diagnosis: 8A564

9D473
Vacuum Control Valve 12A091
DESCRIPTION
The VCV controls vacuum to other emission devices during engine warm-up: the 2-port types
simply open when engine coolant reaches their pre-determined calibration temperatures; the
4-port types open likewise, since they are nothing more than two 2-port types in one housing;
and the 3-port types switch the vacuum source to the center port from the top or the bottom
ports. Electrical switches can be either open or closed until the VCV is fully cycled. The
VCV's respond to a sensing bulb immersed in engine coolant by utilizing a wax pellet principle.
Vacuum is usually sourced as illustrated in Figure 33.
tD473
8A564
A CONNEct'S TO VACUUM DEVICE OR
8 CONNECTS TO VACUUM SOURCE 12A091
A13535-A
Figure 33 2-, 3-, and 4-Port Vacuum Valves
Functional Vacuum Check

1. With a cold engine, passage A to 8 should be closed and passage A to C should be
open.
2. With engine at normal operating temperature, the VCV should be open between A and B
and closed between A and C.
For the 4-port valve, check A, to 8, and A2 to 8 2 separately.
3. If these conditions are not met, replace the VCV Valve.

ALL RIGHTS RESERVED
10-34 Thermactor Systems (Secondary Air Injecti~:m)
Functional Diagnosis: 8A564

90473
Vacuum Control Valve 12A091
Electrical Vacuum Switch
The Electrical Vacuum Switch (Figure 34) could be either opened or closed at room
temperature. It will be reversed (opened to closed or closed to opened) with the engine at full
C (SPARK PORT VACUUM)

--;7 NORMALLY OPEN
/ ' A COMMON PORT
, (DISTRIBUTOR)
~ NORMALLY CLOSED
B (INTAKE MANIFOLD)
A61~
Figure 34 Electrical Vacuum Switch - BA564
Functional Electrical Check
1. While the engine is cold, measure the continuity across the switch. Compare with
specifications.
2. Warm the engine to normal operating temperature.
3. Measure the continuity across the switch. Compare with specifications.
4. The vacuum function is checked as previously described.

ALL RIGHTS RESERVED
Thennactor Systems (Secondary Air Injection) 1035
Functional Diagnosis: 12A197 I ~

. .V. _a_c_u_u_m~C_h_e_c_k_V_al_v_e ....a...- -----I V_CK-_V ~
DESCRIPTION
A Vacuum Check Valve (Figure 35) blocks airflow in one direction. It allows free airflow in the
- - . . . . . . . . DIRECTION OF FREE AIRFLOW
~~.~ VACUUM SlOE

-BlACK
AIOI7-C
DIAGNOSIS

ALL RIGHTS RESERVED
9E453
Vacuum Reservoir VAESEA VRESER
DESCRIPTION
The Vacuum Reservoir (Figure 36) stores vacuum and provides "muscle" vacuum. It prevents
VB
WITHOUT CHECK
VACUUM
OUTPUT
ORIENTATION
POST
CHECK VALVE
AND VACUUM
SUPPLY
WITH CHECK VALVE

A6069C
DIAGNOSIS

ALL RIGHTS RESERVED
g
F_U_D_c_t_iO_D_a_I_D_ia__D_O_S_iS_:
Pulse Air Valve
----&-_9_A_4_8_7--J Ir-----X-\-T---
. \I
....
DESCRIPTION
The Thermactor II (Pulse Air) Control Valve is normally closed. Without vacuum signal from the
solenoid, the flow of air is blocked.
VACUUM NIPPLE
"'FREE REED
"'lIIIIIIII(II FLOW
........ IN
TO CATAlYTIC
CONVERTER
A5962-8
Figure 38 Thermactor" (Pulse Air) Control Figure 39 Pulse Air Valve Thermactor "
Valve
Functional Check
1. Visually inspect the thermactor system hoses, tubes, control valve(s) and check valve(s)
for leaks that may be due to backflow of exhaust gas. If holes are found and/or traces of
exhaust gas products are evident, the check valve may be suspect.
2. As shown in the above illustrations, the valves should allow free flow of air in the
direction of the arrow only. The valve(s) should check (or block) the free flow of exhaust
gas in the opposite direction.
3. Replace the valve if air does not flow as indicated or if exhaust gas backflows opposite
of the direction of the arrow.
4. Remove inlet hose.
5. With engine at normal operating temperature and at idle in NEUTRAL air should be drawn
into the valve.
6. Remove the vacuum line and air flow should stop.
7. If these conditions are met, valve is 'operating properly.
8. If these conditions are not met, verify that vacuum is present at the valve and see
solenoid valve check or Quick Test if vacuum is not present.
9. If vacuum is present but no air flows, check Pulse Air Check Valve, Silencer Filter, and air
cleaner for blocked or restricted passages.
10. If vacuum is present and no blocked or restricted passages are found, replace valve.

ALL RIGHTS RESERVED
SECTION 11
Fuel Delivery Systems
Contents
Notes, Cautions and Warnings .. ~ 11-1
Mechanical Fuel Delivery Systems: System Diagnosis 11-3
Electric Fuel Delivery Systems: System Descriptions 11-5
Electric Fuel Delivery Systems: System Diagnosis 11-22

ALL RIGHTS RESERVED
Notes, Cautions and Warnings
INote I
This test is intended to diagnose the following symptoms:
Cranks normally but won't start
Starts normally but won't run (stalls)
Cranks normally but slow to start
Misses under load
Hesitates or stalls on acceleration
Backfire (induction or exhaust)
Lack of power
Surges at steady speed
Poor fuel economy
Gas smell
Pre-checks:
Verify battery is fully charged.
Check for adequate fuel supply in fuel tank.
. Verify fuse/fuse link integrity.
Inertia switch is set.
Verify engine at operating temperature, transmission in NEUTRAL or PARK and brakes
applied.
Inspect all hoses, fuel lines and fuel tanks for deformities, kinks and leaks.
Check fuel pump and fuel line connections for fuel leaks.
Check fuel pressure regulator CFI/EFI area for fuel leaks.
NOTE: For additional information, refer to Fuel/Engine Group In the Car or Truck Shop
Manual.
SPECIAL SERVICE TOOLS
TOOL NO. DESCRIPTION

014-00447 Fuel Pressure Testing Kit
Digital Volt-Ohm Meter
007-00001 (DVOM)
. 021-00037 Vacuum Tester
Vacuum and Pressure
059-00008
Tester
113-00001 Fuel Injector Tester/Cleaner
- Mechanics Stethoscope

ALL RIGHTS RESERVED
11-2 Fuel Delivery Systems
Notes, Cautions and Warnings
i CAUTION!
Use care to prevent combustion from fuel spillage. No smoking, open flames or any
kind of arcing.
I WARNING I
Fuel in the fuel system remains under high pressure even when the engine is not
running. To avoid injury or fire, release the fuel pressure from the fuel system before
disconnecting any fuel line. To release the pressure from the system perform the
following:
Connect the Rotunda Fuel Pressure Testing Kit, No. 014-00447 or equivalent at the
Schrader valve located on the fuel rail, with the Testing Kit valve closed.
Gradually open the Testing Kit valve to relieve fuel pressure in the vehicle fuel
system and drain the fuel into a suitable container or return it to the fuel tank.
To avoid unnecessary fuel spillage and fire hazard at any time fuel lines are
disconnected, the ignition switch should be in the OFF position unless fuel pump
operation is required for test purposes.

ALL RIGHTS RESERVED
Fuel Delivery Systems 11-3
Mechanical Fuel Delivery Systems:

MFD
System Diagnosis
MFD11 CHECK FUEL PRESSURE
Install fuel pressure gauge at the carburetor. Yes ~ GO to IMFD21.

Reconnect fuel line.
No ~ GO to IMFD31.
Start and run engine' at 1500 rpm for 30 seconds.
With engine at' idle, .read the fuel pressure gauge.
NOTE: If you are here for a no start, Just crank
the engine and read the fuel pressure
gauge 6.0 psi at 10 second cranking.
Is fuel pressure within 6.0-8.0 psi?
MFD21 CHECK FUEL VOLUME
Disconnect primary side of ignition coil. Yes ~ REPLACE fuel filter

and, or SERVICE
Disconnect fuel line at the carburetor. carburetor.
Slide a flexible fuel resistant hose onto the RECONNECT ignition
disconnected fuel line and hold it into a clear coil.
,
plastic fuel resistant container.
Verify smallest diameter in fuel line is greater than
No ~ Go to IMFD61.
0.22 inch.
With a remote starter button, crank the engine.
Is the volume 0.3 plnt/10 seconds?
Save fuel in container for IMFD61 . '.
MFD31 CHECK AUXILIARY FUEL SUPPLY
Use an auxiliary fuel supply and route the flexible Yes ~ RECONNECT the fuel
fuel line under the fender or bumper to the inlet line at the fuel pump.
side of the fuel pump. GO to IMFD41.
Repeat Test IMFD11 and IMFD21 .

No ~ REPLACE fuel pump
Is fuel pressure at least 6.0 psi and fuel and fuel hose.
volume 0.3 pint/10 seconds?

ALL RIGHTS RESERVED
Mechanical Fuel Delivery Systems:

MFD
System Diagnosis
MFD41 CHECK FUEL LINE
Disconnect the fuel line at the tank. Yes ~ GO to IMFDSI.

Connect auxiliary fuel supply to the fuel line.
No ~ BLOW OUT fuel line.
Repeat Test IMFD1 I and IMFD21 . SERVICE fuel line.
REPLACE flexible
Is fuel pressure at least 6.0 psi and fuel hoses.
volume 0.3 pint/10 seconds?
MFDSI CHECK FUEL TANK SENDER UNIT
Drain fuel tank, but not' completely. Yes ~ REPLACE the fuel
sender unit.
Disconnect fuel return line if applicable.
Disconnect fuel sender unit. No ~ GO to IMFDSI.
Disconnect evaporative system from fuel tank.
Lower the fuel tank and remove sender unit.
Inspect sender unit for being bent, blocked or
rusted through.
Is fuel sender unit defective?
MFDSI CHECK FUEL CONTAMINATION
Check remaining fuel in the tank for Yes ~ DUMP/FLUSH the fuel
contamination. tank.
BLOW OUT the fuel
Check the fuel sample from test IMFD21 for lines.
contamination. REPLACE fuel filters.
CLEAN out carburetor.
Is the fuel contaminated?
No ~ Problem may be
elsewhere.
, . GO to Section 2.

ALL RIGHTS RESERVED
Electric Fuel Delivery Systems:

EFD
System Descriptions
VEHICLE APPLICATION
F-; E-Series: 4.9L, 5.0L, 5.8L, 7.5L EFI

Bronco: 4.9L, 5.0L, 5.8L EFI
Ranger, Bronco II: 2.3L, 2.9L, 4.0L EFI
Aerostar: 3.0L, 4.0L EFI
Passenger Car: All with EFI/CFI
Types of Systems
Fuel delivery systems using Electronic Fuel Injection (EFI) differ in their design and
arrangement, depending upon the vehicle' and model year. To clarify understanding and to
simplify diagnostic instruction they are classified by Types 1 through 5, as shown in the
System Schematics, are listed as follows:
Type 1 Single Tank, Single Pump

Type 2 Single Tank, Dual Pump
Type 3 Dual Tank whh Electric Selector Valve
Type 4 Dual Tank with Mechanical Selector Valve/Reservoir
Type 5 Dual Tank with Pump Sender In-Tank-Reservoir (ITR).
For supplying the fuel injectors continuously with clean ,fuel at a controlled high pressure, all
such systems require a high-pressure fuel pump with discharge check valve, a reservoir near
the pump inlet, a fine mesh fuel filter, a pressure regulator, a fuel supply and return system, a
fuel tank, and a fuel supply manifold or fuel rail connected to the fuel injectors. The Electronic
Control Assembly (ECA) controls power input to the fuel delivery system and provides correct
timing for the fuel injectors.
Low-Pressure Fuel Pump
All fuel systems with EFI require a high-pressure pump,' but some are two-pump systems
having a primary, or low pressure in-tank pump for supplying fuel to the reservoir (Types 2, 3,
& 4 Systems). The Low-Pressure Pump rests in a sump, or depression, in the fuel tank. A
nylon screen protects the low-pressure pump inlet from contaminating particles, but allows the
passage of small amounts of water which may 'accumulate in the fuel tank sump. When dual
tanks are used, each tank is equipped with its own low=-pressure pump, making a total of
three pumps in the system, two low-pressure and one high-pressure.

ALL RIGHTS RESERVED
11-6 fuel Delivery System.

EFD
System Descriptions
High-Pressure Fuel Pump
Type 1 Systems use a single pump, wherein the low-pressure in-tank pump is not used, but is
replaced by a High-Pressure In-Tank Pump. It is capable of pumping in excess of 60 liters (16
gal.) of fuel per hour at a working pressure of 270 kPa (39.2 psi) and has an internal
pressure relief valve, set to 850 kPa (123 psi) to protect against over-pressure due to fuel
flow restriction. It also has a discharge check valve (to maintain system pressure during
shutdowns and to minimize starting problems) and an inlet screen for protection.
Types 2, 3, and 4 Systems use two pumps with a low-pressure in-tank pump, a High-Pressure
In-Line Pump mounted inside the left frame rail and a reservoir in-line between the two. Other
High-Pressure Pumps used in these systems are 80 liter (21 gal) and 100 liter (26 gal)
minimum per hour capacities, depending upon the vehicle application. These pumps also have
internal relief valve and discharge check valve.
A10012A
Figure 1 High-Pressure and In-Tank Fuel

Pump

ALL RIGHTS RESERVED

EFD
System Descriptions
Reservoirs and Filters
Fuel reservoirs are used to prevent fuel flow interruptions during extreme vehicle maneuvers
with low tank fill levels. In-line reservoirs (Types 2, 3, & 4) are frame mounted and are always
located between the low and high-pressure pumps. If the high-pressure pump is located in-tank
(Type 1 and 5), the reservoir is either molded or welded into the tank or into the fuel pump
and sender plastic housing. In-line reservoirs are of two types, the standard single function
design used with Types 2 and 3 Systems or the dual function design having the integral
mechanical selector valve (Type 4 System). The standard single function reservoir, used on
Type 2 and 3 systems, may contain a fine mesh in-line filter located between the high-
pressure pump and the fuel rail. Simultaneously, a fine screen was added to the high-pressure
pump inlet.
Selector Valves (Dual Tank Only)
Selector valves are used on F- and E-series and on Ranger vehicles equipped with dual fuel
tanks (Types 3 and 4 Systems). A driver operated selector switch controls the Selector Valve
for switching the fuel supply from one tank to the other. Two types of valves are used,
electrical (Type 3) or mechanical (Type 4). The electric valve, when energized by the selector
switch, moves its valve to shut off the supply and return lines from one tank and to open the
lines to the other tank. Simultaneously the in-tank pump and fuel level sender are turned off
for one tank and energized for the other. The Mechanical Selector Valve is contained within
the six-port reservoir assembly (the so-called "dual function reservoir"), is identified in these
diagnostics as "Mechanical Selector Valve/Reservoir", and is used in the Type 4 system only.
It switches fuel supply and return lines from one tank to the other in response to fuel
pressure from in-tank pumps acting on its actuating diaphragm. The diaphragm switches tank
connections under 2 psi of fuel pressure acting on its upper side for the front tank and on its
lower side for the rear tank. Good valve functioning depends upon proper operation of the in-
tank low-pressure pumps. In all dual tank vehicles, excess fuel not used by the engine is
returned to the same tank from which it was pumped.
Dual Tank with Pump Sender In-Tank-Reservoir (ITR) Only
High Pressure Fuel Pump
Type 5 systems use a High Pressure Fuel Pump' inside the fuel tank similar to a Type 1
pump. Type 5 systems have a reservoir built onto the pump and sender assembly instead of
being part of the tank. In the event of a two tank system, the sender assembly handles the
switching of the High Pressure Fuel through internal valves. If you have a type 5 system with
two tanks and one tank overfills during use (return line returns fuel to wrong tank) it will be
necessary to change the pump and sender unit in the tank that overfills. The fuel pump is
capable of pumping in excess of 125 liters (33 gaL) of fuel per hour at a working pressure of
270 kPa (39.2 psi). These pumps also have internal pressure relief and discharge check
valves.

ALL RIGHTS RESERVED

EFD
System Descriptions
Shuttle Selector Valve
The Shuttle Selector Valve opens the return line to the tank when the diaphragm force,
resulting from the fuel pressure applied to the shuttle diaphragm, exceeds the opposing spring
force. Thus, the return flow is directed to the appropriate tank on vehicles equipped with dual
tanks.
Supply Check Valve
The Supply Check Valve, which is normally closed, opens when the outlet pressure from the
energized pump exceeds the opposing check valve spring force. When the pump is de-
energized (Le., engine is shutoff), the supply check valve closes to maintain pump prime and
fuel supply line pressure.
Venturi Jet Pump
A portion of the high pressure flow from the pump is diverted to operate the Venturi Jet
Pump. The Venturi Pump draws fuel from the tank into the ITA reservoir to augment the
engine return flow. This process ensures an adequate fuel supply to the pump during extreme
vehicle maneuvers and steep vehicle attitudes with low-tank fill levels.
The inlet of the Venturi Pump has a nylon filter on it to prevent dirt and other particulate
matter from entering the system. Any water accumulation in the fuel tank can pass through
the filter without restriction.
NOTE The ITR Is not a separately serviceable component.
FLOW FROM ENGINE
FLOW 10 ENGINE
HIGH PRESSURE PUMP

CHECK VALVE SHUTILE VALVE
DIAPHRAGM
HIGH PRESSURE PUMP
VENTURI JET PUMP
PUMP FILTER SCREEN -----1!t1!"~~

u.::::==~~~~1.-.
CHECK VALVE
VENTURI FILTER SCREEN

A12788-A
Figure 2 Pump Sender In-Tank-Reservoir (ITR) Components and Flow Path

ALL RIGHTS RESERVED

EFD
System Descriptions
Fuel Pressure Regulator - EFI System
The Fuel Pressure Regulator (Figure 3) is attached to the fuel supply manifold assembly down
stream of the fuel injectors. It regulates the fuel pressure supplied to the injectors. The
regulator is a diaphragm-operated relief valve. One side of the diaphragm senses fuel pressure
and the other side is subjected to intake manifold vacuum. The nominal fuel pressure is
established by a spring preload applied to the diaphragm. Balancing one side of the diaphragm
with mani.fold vacuum maintains a constant fuel pressure drop across the injectors. Fuel in
excess of that used by the engine is bypassed through the regulator and returns to the fuel
tank.
1....._ _ ENGINE VACUUM

REFERENCE TUBE
SPRING
UPPER
HOUSING
FUEL
FILTER
DIAPHRAGM.
SCREEN
@!1t~~~~~l~_LOWER HOUSING
O-RING IIWII-..._ FUEL OUTLET

GROOVE TUBE (RETURN)
FUEL INLET TUBE
(SUPPLY) A12n2A
Figure 3 Fuel Pressure Regulator
Test Point
A pressure test point, equipped with a Schrader fitting, is provided in the engine fuel rail for
the purpose of relieving pressure in the fuel system and for measuring the injector supply
pressure for service and diagnostic work. Refer to Notes, Cautions and Warnings.
Fuel Pump Circuit Operation
When the ignition is switched to the ON position, it turns the EEC Power Relay on. The EEC
Power Relay provides power to the Electronic Control Assembly (ECA) and the control side of
the fuel pump relay. Power for the fuel pump(s) is supplied through a fuse link or high current
fuse attached to the starter solenoid (battery side). From the fuse link or high current fuse
current flow is through the fuel pump relay and inertia switch to the fuel pumps(s). The inertia
switch is a safety device used to shut off the fuel pump(s) in the event of a collision. If the
inertia switch is "tripped" it must be reset by depressing the white or red button on the top
of the switch. The fuel pump relay is controlled by the ECA.
When the ignition switch is turned to the ON position, the fuel pump(s) will operate. If the
ignition switch is not turned to the START position the ECA will shut the fuel pumps off after
approximately one second. The ECA will operate the fuel pump(s) when the ignition is in the
START position. to provide fuel while cranking.
After the engine starts, the ECA will continue to operate the fuel pump(s) unless the engine
stops or engine speed drops below 120 rpm, or the inertia switch is "tripped".

ALL RIGHTS RESERVED
.11-10 Fuel Delivery Systems

EFD
System Descriptions
Inertia Switch
The Inertia Switch (Figure 4) is used in conjunction with an electric fuel pump. The purpose of
the Inertia Switch is to shut off the fuel pump in the event of an accident. It consists of a
steel ball held in place by a magnet. When a sharp impact occurs, the ball. breaks loose from
the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical
contacts of the switch and thereby shuts off the electric fuel pump. Once the switch is open,
it must be manually reset before restarting the vehicle. The location of the switch is discussed
in the Owner's Manual. .
RESET ~UTTON
TARGET
PLATE
1'-'___._
L_.J_~
POSITION FOR
OPEN SWITCH
CLOSED
SWITCH
ELECTRICAL
CONTRACTS o
SWITCH
TERMINALS
EXTERNAL VIEW A7194-D
CUTAWAY VIEW
Figure 4 Inertia Switch

Reset Instructions
1. Turn ignition to OFF.
2. Check for leaking fuel in the engine compartment, fuel lines and tank(s).
3. If no fuel leak is apparent, reset the switch by pushing the reset button on the top of the
switch (Refer to Owner's Manual).
4. Turn ignition switch to START for a few seconds, then to OFF.
5. Again, check for leaking fuel.
I WARNING I
IF YOU SEE OR SMELL GASOLINE AT ANY TIME OTHER THAN DURING FUELING, DO
NOT RESET THE SWITCH.
Functional Check
Push down on the reset button to make sure the switch is closed.
Use DVOM, Rotunda 007-00001 or equivalent, with LOS button On and measure voltage
across both terminals of the inertia switch. If DVOM reading is greater than O.3V, replace the
inertia switch.
NOTE: In the closed position, the button can be depressed an additional 1/16-inch
against a spring. This is a normal condition and does not adversely effect the
switch operation.

ALL RIGHTS RESERVED

EFD
System Descriptions
Fuel Injector
The Fuel Injector (Figure 5) is a solenoid operated valve that meters fuel flow to the engine.
The injector is opened and closed a constant number of times per crank revolution. The
amount of fuel is controlled by the length of time it is held open.
The injector is normally closed and is operated by a signal from the Electronic Engine Control
(EEC) module.
INTEGRAL FILTER
FUEL RAIL O-RING
SEAL
COIL
........",_-.STA1NlESS
STEEL
NEEDLE
PtNTLE PROTECTION CAP

PINTLE LOW-PRESSURE CFI (1.9L ONLY)
HIGH-PRESSURE EFt HIGH-PRESSURE CFl (2.5L ONLY)
A7186-C A9382-D
Figure 5 Fuel Injectors

ALL RIGHTS RESERVED

EFD
System Descriptions
THE MAJORITY OF THE FUEL METERING FUNCTION IS

MOVED WITH THE INJECTOR AND IS HANDLED BY AN
INTERNAL UPSTREAM ORIFICE INSERTED INTO THE
ADJUSTING TUBE.
DEPOSIT RESISTANT INJECTOR (DRI)

METERING ASSEMBLY
THE REMAINING METERING OF FUEL IS STILL

ACCOMPLISHED AT THE PINTLE/SEAT ASSEMBLY -
BUT NOW ITS VARIATIONS AFFECT ONLY A FRACTION
OF THE TOTAL FUEL FLOW.
TOP FEED STAGE III
DIAECTORIMETEAING PLATE TOP FEED STAGE'" (TOSK II)
A127&7A
Figure 6 Deposit Resistant Injector (DRI) Designs
NOTE: Low-pressure Injectors have low coli resistance. High-pressure Injectors can have
either high or low coli resistance. Function can be adversely affected by using
the wrong Injectors.
NOTE: Do not apply battery voltage directly to the Injector electrical connector
terminals. The solenoid may be damaged Internally in a matter of seconds.
For EFI injectors, refer to Section 4, Fuel Injector Testing/Cleaning.

ALL RIGHTS RESERVED

EFD
System Descriptions
TYPE 1 - SINGLE TANK, SINGLE PUMP

RETURN
FUEL
FLOW~
FILTER
FUEL TANK
~ FLOW
I~ I INLET
HIGH PRESSURE ~ LI FILTER
PRESSURE FUEL PUMP AND ~
PRESSURE INJEC10RS
TEST POINT RESERVOIR
REGULATOR
A8576-A
. Figure 7 Type 1 - Single Tank, Single Pump
VEHICLE APPLICATION
Passenger Car EFI/CFI.
Aerostar, EFI.
Ranger, Br~nco II, 1989 and later model years, and F-Series/Bronco 90 mod~1 year.
TYPE 2 - SINGLE TANK, DUAL PUMP
FLOW ~
-r-ch -
FILTER
~
H 11 BOOST
FLOW ~PUMP
PRESSURE , i INLET
TEST POINT ~FILTER
I"'!JECTORS HIGH PRESSURE SINGLE FUNCTION

FUEL PUMP RESERVOIR
A8571A
Figure 8 Type 2 - Single Tank - Dual Pump
VEHICLE APPLICATION
F-Series/Bronco, 1985-89 model years, EFt.
Ranger/Bronco II, 1985-89 model years, EFt.

ALL RIGHTS RESERVED

EFD
System Descriptions
TYPE 3 - DUAL TANK WITH RETURN

ELECTRIC SELECTOR VALVE FUEL
.1 BOOST
.iL/'PUMP
FLOW'"
, I INLET
L~_'" -r-~-
~FILTER
FILTER
FRONT
TANK
RETURN
~ FLOW /FUEL
REGULATOR
r---y
PRES.SURE L .. J r ,.-~"+-t+---_
TEST POINT
L_ ..J " BOOST
J1.. PUMP
INJECTORS
RESERVOIR
I I INLET
REAR
TANK
~FILTER
1.85721.
Figure 9 Type 3 - Dual Tank with Electronic Selector Valve
VEHICLE APPLICATION
F-Series 1985 model year, EFI.
E-Series 1986-87 model years, EFI.
Ranger 1985-88 model years, EFI.
TYPE 4 - DUAL TANK WITH ,......--_RETURN

MECHANICAL SELECTOR VALVEIRESERVOIR FUEL
,........~~---
" BOOST
~PUMP
FLOW'" *=;~====~ TANK
FRONT
I I INLET
FILTER
~FILTEA
~-
REGULATOR
-r-
PRESSURE
TEST POINT
ch - ,
. . FLOW
PRESSURE
-...:::::::::~..-..,-'
I I
I I
L.t---
- -.,
-I RETURN
FUEL
INJECTORS HIGH PRESSURE LINE (FUEL)

FUEL PUMP I' BOOST
~PUMP
MECHANICAL
REAR
TANK
NOTE: MECHANICAL SELECTOR VALVE IS CONTROLLED BY PRESSURE SELECTOR
VALVEJRESERVOIR I INLET
FROM LOW PRESSURE FUEL PUMp. ONLY ONE SET OFPAESSURE ~FILTER
AND RE1URN LINES 18 ACTIVE AT A TIME. 1.8573-1.
Figure 10 Type 4 - Dual Tank with Mechanical Selector Valve/Reservoir
VEHICLE APPLICATION
E-Series 1988 and later model years, EFI.
F-Series 1986-89 model years, EFI.

ALL RIGHTS RESERVED
Fuel. Delivery Systems 11-15

EFD
System Descriptions
RETURN
FUEL
ITR UNIT
FLOW ~ INLET
FILTER
, FILTER
-\tFL~
I MAIN TANK
I
: I
I I RETURN
I I . '---FUEL
I '----~
PRESSURE - - - -~--:.'1"'1I1
r --_ _
LINE (FUEL) :. ITR UNIT
INJECTOR PRESSURE
TEST POINT
"-
~-
SECONDARY TANK
A12nO-A
Figure 11 Type 5 - Dual Tank, Single Pump System In-Tank-Reservoir (lTR) Only.
VEHICLE APPLICATION
F-Series - 1990 Model Year EFt

ALL RIGHTS RESERVED
1116 Fuel Delivery Systems

EFD
System Descriptions
Electrical Schematic
tHOT AT ALL TIMES I ~
r~~EM~
20 GA. BLUE
INERTIA
SWITCH
I SINGLE TANK
TYPE 1
OPENS [ ] ]
1: ~NpACTI FUEL PUMP MONITOR
~~~:y I{r------u----r{ I b ~~;~~t:IC

INERTIA
r: I (ECA)
T r1~37:L5?=7-L.8~-----,t
gE~~CSH ~ i-{122 )
IMPACT ,l
TO
I
VIP
ELECTRIC ~ TEST
FUEL ~ CONNECTOR
PUMP
~ A8574-B
Figure 12 Type 1-Single Tank
VEHICLE APPLICATION
Passenger car EFIICFI, except 3.0L SHO
Aerostar, 1986 1/2 and later model years, EFI
Ranger/Bronco II, 1989 model year, EFI
* Inertia switch located in line with fuel pump on 1989 Bronco II and 1986 1/2-89 Aerostar.

ALL RIGHTS RESERVED

EFD
System Descriptions
IHOT AT ALL TIMES!

YIP SELF-TEST OUTPUT
CONNECTOR
C1984
97
T/lG 38 BKIO
~~~BOOWN
FUSE
Fo::r
UNK
J
f
97 T/lG
BKIO
MB~ 38 8K10
MB~ ~lR
,~ ,I"
18 1 2 12 24
INTEGRATED
CONTROL
10 MODULE 5
'i'
787rKlBK
787
5403
~;fK1BK PKlBK
C123
922 WfR
78fKIBK
ELECTRONle
CONTROL
ASSEMB LV
I C1rj" INERTIA
(ECA) 37
~~
57 19
~
rn
..!:~
--.:;;-
LOW SPEED
FUEL PUMP
RESISTOR
781PI<IBK
SWITCH
OPENS ON
IMPACT
~~l
787 PKlBK
38 BKIO I I M FUEL
I I PUMP
~~
8166-
57lBK
~G104
A12771-A
Figure 13 Type 1 - Single Tank
VEHICLE APPLICATION
3.0L SHO Taurus/Sable 1990.

ALL RIGHTS RESERVED

EFD
System Descriptions
[HOT"AT ALL TIMES I

ELECTRONIC
o
I\)
ENGINE o
CONTROL G> FUSE
(VPWR PIN 37/57)
"!> L1NKQ
lJJ
r
t i
If--------mu----- --II FUEL
PUMP
RELAY
1
~~~~r'c ~I
INERTIA
SWITCH
OPENS ON
IMPACT
FUEL PUMP
MONITOR PIN 22
_______A""' --.~. ~~~~

1 I
r I
r--!puMP----p--l
~
HRIGEHSSURE FUEL
I__--(,2--- r
P
: M SENDER '. TANK
PUMP
T__~ ,-__ mu J
UNIT
V
y
I
I
: A8575B
Figure 14 Type 2-Single Tank
VEHICLE APPLICATION
E-Series, 1986-89 model year, EFI.
F-Series, Bronco, 1985-89 model years, EFI.
Ranger, 1985-1989 model years, EFI.
Aerostar, early 1986 model year, EFI.
Bronco II 1985-88 model year, EFI.

ALL RIGHTS RESERVED
Electric Fuel Delivery .Systems:

EFD
System Descriptions
IHOT AT ALL TIMES I

ELECTRONIC o
ENGINE ~
CONTROL
(VPWR PINS 37/57) ~ FUSE
CD L1NKQ
r
c
m
FUEL
PUMP
RELAY
ELECTRONIC
ENGINE
CONTROL
FUEL PUMP MONITOR
rnI INERTIA
SWITCH
OPENS ON
IMPACT
PIN 22
FUEL
TANK
SELECTOR
SWITCH
I .....
.I
"'y"
,
I
I
~-,
"
" ....
"'
I
I
L
Ir t - - -PUMP
I M
L
-p,REAR
~~~E.!3.
----------------~
I FUEL
J TANK
UNIT
A8826B
Figure 15 Type 3-Dual Tanks

. ':'
VEHICLE APPLICATION
F-Series 1985 model year, EFI.
E-Series 1986-87 model years, EFI.
Ranger 1985-88 model years, EFI.

ALL RIGHTS RESERVED

EFD
System Descriptions
IHOT AT ALL TIMES I
ELECTRONIC
o
ENGINE ~
CONTROL G)
(VPWR PINS 37/57) ~
~ FUSE
C lINKQ
m
FUEL
PUMP
~~ '"""I!I~ RELAY
ELECTRONIC
ENGINE
CONTROL
rnI INERTIA
SWITCH
OPENS ON
IMPACT
FROM
FUEL GAUGE
FUEL PUMP
MONITOR PIN 22
FUEL TANK
SELECTOR
SWITCH
1
r---
Ir~--1'
PUMP I FUEL
REAR
M TANK
IL SENDER
__ ,*,JI UNIT
'-------+-- _---..IT J
A8828B
Figure 16 Type 4 - Dual Tanks
VEHICLE APPLICATION
E-Series 1988 and later model years, EFI.
F-Series 1986 to 1989 model years, EFI.

ALL RIGHTS RESERVED

EFD
System Descriptions
IHOT AT ALL TIMES I

ELECTRONIC
o
N
ENGINE o
CONTROL G)
(VPWR PINS 37(57) ~
~ FUSE
~ L1NKQ
FUEL
PUMP
~'r----------~ RELAY
ELECTRONIC
ENGINE
CONTROL
rnI INERTIA
SWITCH.
OPENS ON
IMPACT
FROM
FUEL GAUGE
FUEL PUMP
MONITOR PIN 22
FUEL TANK
SELECTOR
SWITCH
A8828B
Figure 17 Type 5 - Dual Tanks
VEHICLE APPLICATION
F-Series1990 model year, EFI.

ALL RIGHTS RESERVED
. Electric Fuel Delivery Systems:

EFD
System Diagnosis
FUEL PRESSURE SPECIFICATION TABLE

1990 Passenger Car Engines
1.9L/2.5L 2.3L 3.0L 3.8L All
HSC SHO SC Other
CFI EFI SEFI SEFI Applications
ENGINE 13 -17 PSI 45-60 PSI 28-33 PSI 30-40 PSI 30-45 PSI
RUNNING 90 -120 kPa 310-415 kPa 193-227 kPa 210-280 kPa 210-310 kPa
KEY ON 13 -17 PSI 50-60 PSI 30-45 PSI 35-40 PSI 35 -40 PSI
ENGINE OFF 90 -120 kPa 345-415 kPa 210-310 kPa 240-280 kPa 240-280 kPa
1990 Light Truck Engines

4.9L All
Other
EFI Applications
ENGINE 45-60 PSI 30-45 PSI
RUNNING 310-415 kPa 210-310 kPa
KEY ON
....-------+---------4
50-60 PSI 35-45 PSI
ENGINE 345 - 415 kPa 240-310 kPa
OFF
NOTE: Except for eFI systems; maximum fuel pressure is obtainable at WOT or the
vacuum hose removed from the fuel pressure regulator.
FP LEAD
(SHORT END
OF CONNECTOR)
A9465-8
Figure 1 Self Test Connector

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD11 SYSTEM INTEGRITY CHECK

(ALL TYPES)
Visually inspect the complete fuel delivery system, Yes ~ GO to IEFD21.

including fuel tank lines, reservoir, filter, pumps,
injectors, pressure regulator, battery, electrical No ~ REPAIR or REPLACE
lines and connectors for leakage, looseness, as required.
cracks, pinching, kinking, corrosion, grounding,
abrasion, or other damage caused by accident,
collision, assembly or usage.
Verify that the battery is fully charged.
Check the engine fuse integrity.
Check for sufficient fuel in the fuel tanks.
Is the system free of any evidence of leakage,
damage, or any other cause for concern?
I WARNING ,
BEFORE SERVICING OR REPLACING ANY

COMPONENTS IN THE FUEL SYSTEM, REDUCE
THE POSSIBILITY OF INJURY OR FIRE, AS
OUTLINED UNDER "NOTES, CAUTIONS AND
WARNINGS".
EFD21 FUEL INJECTION PRESSURE TEST

(ALL TYPES)
Key Off Yes ~ ~e1 or 5: GO to

EFD47 .
Ground the fuel pump lead of the Self-Test
connector (Figure 1 on next page) through a For all other types: GO
jumper at the FP lead. to IEFD401.
Before releasing fuel system pressure at the
Schrader fitting, observe the Warning Instructions No ~ If zero, GO to IEFD31 .
to avoid fuel spillage and injury.
If low, GO to IEFD26 I.
Install the fuel pressure tester.
Key On, Engine Off, to operate the fuel pump(s). ~GOto
EFD38 .
Verify that the observed fuel pressure is within
specified limits for the engine being checked.
Specification: Fuel System Pressure (Key On,
Engine Off) Refer to "Fuel Pressure Specification
Table."
Is the fuel pressure within specification?

ALL RIGHTS RESERVED
11-24 - Fuel- Delivery Systems

EFD
System Diagnosis
EFD31 VERIFICATION OF SYSTEM TYPE
Verify if vehicle is a single pump system (Type- 1) Single Pump ~ GO to IEFD161.

or dual pump (types 2, 3, 4, 5) system. (Type 1)
Type 1 - Single Tank, Single Pump.

Dual Pump ~ GO to IEFD41.
Type 2 - Single Tank, Dual Pump. (Types 2, 3, 4)
Type 3 - Dual Tank, Dual Pump Electrical
Selector Valve. Dual Tank ~ GO to IEFD61.
Single Pump
Type 4 - Dual Tank, Dual Pump Mechanical (Type 5)
SelectorI Reservoir.
Type 5 - Dual Tank, Single Pump (ITR)
EFD41 VOLTAGE CHECK AT H.P. PUMP

(TYPES 2, 3, 4)
Key Off: Yes GOto~.

Battery fully charged.
No GO to IEFD191.
Ground the fuel pump lead of the VIP Self-Test
connector as shown.
Key On, Engine Off.
Disconnect electrical high-pressure fuel pump at
connector.
DVOM on 20 volt scale.
Measure the voltage on the harness side as
shown.
Is the voltage greater than 10.5 volts?
~ ~HEk)
GROUNDING
PROBE
~~ VIP SELF-TEST
{l
~
~
_ c:::f~
A8829-A

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD5 HIGH PRESSURE PUMP GROUND CHECK

(TYPES 2, 3, 4)
Key Off. Yes Go to IEFD61.

Disconnect high-pressure pump at connector.
No REPAIR black wire
DVOM on 200 ohm scale. from high-pressure
Measure the resistance from the black wire to pump to ground as
ground as shown. required.
Is the resistance less than 5 ohms?
EFD6 LOW PRESSURE PUMP VOLTAGE CHECK

(TYPES 2, 3, 4, 5)
Battery fully charged. Yes ~ GO to IEFD91.

Ground the fuel pump lead of the VIP Self Test
connector as shown. No For type 4 or 5, GO to
IEFD71.
Key On, Engine Off.
~e 3, GO to
Place selector switch in "F" position if equipped
with dual tank. ~.
Disconnect the front fuel tank electrical connector. For type 2, REPAIR
wire from low pressure
DVOM on 20 volt scale. fuel pump to inertia
Measure the voltage on the power supply lead to switch as required.
fuel pump as shown.
Repeat procedure with selector switch in "R'"
position and measure voltage at rear tank sender/
pump unit connector.
A8831A

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD71 VOLTAGE CHECK AT SELECTOR SWITCH

(TYPE 4 OR 5)
Key Off. Yes ~ REPAIR wire from

selector switch to front
Battery fully charged. tank pump.
Ground fuel pump lead of the VIP Self-Test
connector as shown. No ~ GO to IEFDSI.
Key On, Engine Off.
Place selector switch in "F" position
Measure voltage at pin 1 of the selector switch
as shown.
Repeat with selector switch in "R" position for
AFT axle tank and measure voltage on Pin 3 as
shown.
~GR~UNO::
VIP SELF TEST PROBE
SELECTOR SWITCH
CONNECTOR A8832A

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD8 VOLTAGE CHECK OF SUPPLY TO SELECTOR

SWITCH (TYPE 4 OR 5)
Key Off. Yes REPLACE selector

switch.
Battery fully. charged.
connector as shown. No SERVICE wire from
selector switch to
Key On, Engine Off. inertia switch.
Disconnect selector switch.
DVOM 'on 20 volt scale.
Measure voltage at Pin 2 of selector switch as
. shown.
Is the Yoltage greater than 10.5 Yolts?
00
VIP SELF -rEST
CONNECTOR
SELECTOR SWITCH
CONNECTOR
A8833-A
EFD9 LOW PRESSURE PUMP(S) GROUND CHECK

(TYPES 2, 3, 4, 5)
Key Off. Yes . For types 2, 4 or 5,

Disconnect electrical connector from front fuel GO to 'I EFD27 I.
tank.
~e3,GOto
DVOM on 200 ohm scale. Lmffi!.J .
Measure the resistance from the tank connector
to ground as shown. No REPAIR wire from fuel
Is the resistance less than 5 ohms? pump/sender connector
to ground.
Repeat for rear tank.
SENDER
SIGNAL
PUMP
W~o*I~---POWER
SENDER/PUMP CONNECTOR A8834-A

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD101 FUEL PUMP(S) OPERATIONAL AUDIBLE

CHECK (TYPE 3)
Key Off. Yes ~ GO to IEFD11\.

Ground the fuel pump lead of the VIP Self-Test No ~ REPAIR fuel pump/
connector as shown. sender unit.
Verify that there is a good electrical connection to
the fuel pump/sender unit.
Key On, Engine Off.
Listen to fuel pump(s).
Are the fuel pump(s) running?
gCHRfu GROUNDING
r===J~
PROBE ~
A8835-A
EFD111 SELECTOR VALVE FUNCTION CHECK

(TYPE 3)
Remove selector valve from vehicle. Yes ~ GO to IEFD271.

Verify selector valve operation by chart shown.
Does the selector valve operate properly? No ~ REPLACE selector
valve.
--
Selector Valve Elec. Table Fuel Flow

Apply Voltage Measure Resistance Check Flow
Valve
At Pins On Pins of Ports
Position
1 2 3
I
Less than
4 5
Front
Port I Pump
Port
Rear
Port
Front (-) (+)

1.0 OHM
Open Connected Blocked
Rear (+) (-) Open

I Less Than
1.0 Ohm Blocked I Connected

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD12 VOLTAGE CHECK AT SELECTOR VALVE

. (TYPE 3)
Key Off. Yes REPAIR wire(s) from

selector valve/switch to
Battery fully charged. low pressure pump.
Connector. No ~ REPAIR ground wire
circuit to selector
Selector switch in front position. switch, and/or GO to
Disconnect selector valve connector. IEFD131.
Key On, Engine Off.

DVOM or 20 volt scale.
Measure voltage on Pin at selector valve as
shown.
Key Off.
DVOM on 200 ohm scale.
Measure resistance from Pin 2 to ground as
shown.
Is the voltage greater than 10.5 volts and the
resistance less than 1 ohm?
Repeat with selector switch in rear position and
measure voltage on Pin 2 of. the selector valve/
switch and resistance from Pin 1 to ground.
A8879A

ALL RIGHTS RESERVED

EFD
System Diagnosis
TEST STEP. RESULT ACTION TO TAKE

(TYPE 3)
Key Off: Yes REPAIR wire(s) from

selector switch to
Battery fully charge~. selector valve.
Ground fuel pump lead of the VIP Self Test
connector. No GO to IEFD141.
Key On, Engine Off.
Selector switch in front position.
Measure voltage on Pin 2 at the fuel tank
selector switch as shown.
'S the voltage greater than 10.5 volts?
Repeat with switch in rear position and measure
voltage on Pin 1 selector switch as shown.
A8880A
RESISTANCE CHECK AT SELECTOR SWITCH

(TYPE 3)
Key Off. Yes GO to IEFD1SI.

Disconnect selector switch from harness.
No REPAIR open wire
DVOM on 200 ohm scale. from switch to ground.
Check resistance from selector switch connector
to ground as shown.
Is the resistance less than 1 ohm?
A8881A

ALL RIGHTS RESERVED

EFD
System Diagnosis

I (TYPE 3)
Ground fuel pump lead of the VIP Self-Test Yes ~ REPLACE switch.
connector.
Key On, Engine Off. No ~ REPAIR wire from
inertia switch to
DVOM on 20 volt scale. selector switch.
Measure the voltage at the selector switch as
shown.
-~
-~ A8882A
EFD161 PUMP OPERATION CHECK, AUDIBLE (TYPE 1:

I AND 5)
Key Off. Yes ~ GO to IEFD271.

No ~ GO to IEFD171.
connector.
Verify that a good electrical connection is made
to the pump/sender unit.
Key On, Engine Off.
Listen to fuel p~mp.
Is the fuel pump running?

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD17 HIGH-PRESSURE PUMP GROUND CHECK

(TYPE 1 AND 5)

Disconnect pump/sender unit connector.
No ~ REPAIR open wire to
DVOM on 200 ohm scale. ground.
Measure the resistance of the wire to ground as
shown.
Is the resistance less than 1 ohm?
SENDER
SIGNAL
i-t'"'---H~::t----- PUMP
POWER
A8884-A
EFD18 VOLTAGE CHECK AT HIGH-PRESSURE PUMP

(TYPE 1 AND 5)
Key Off. Yes ~ REPLACE pump/sender

assembly.
Disconnect pump/sender assembly connector. No ~ GO to IEFD191.
connector.
Key On, Engine Off.
Measure the voltage at the fuel pump/ sender unit
as shown.
SENDER
GROUND
SENDER
--e::::l-+-+-+c>It-i+---- SIGNAL
:t-T~~=r-- __ PUMP
POWER
PUMP GROUND
A8885-A

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD19 VOLTAGE CHECK AT INERTIA SWITCH

(ALL TYPES)
Key Off. Ves ~ For TYRe 5:

Battery fully charged. GO to IEFD71.
Ground fuel pump lead of the VIP Self-Test For all other Types:
connector as shown. . REPAIR the wire from
Key On, Engine Off. the inertia switch to
Inertia switch connected. the high-pressure
pump.
Measure the voltage at the inertia switch as
shown.
DVOM on 20 volt scale. No
Is the voltage greater than 10.5 volts at both
pins?
Repeat for opposite pin of inertia switch as
shown.
A8886-A
EFD20 VOLTAGE CHECK AT SWITCHED SIDE OF F.P.

RELAV (ALL TV.PES)
Key Off. Yes ~ REPAIR brown wire

Battery.fully charged. from fuel pump relay to
inertia switch.
connector as . shown..
Key O~t Engine Off. No GO to IEFD21 I.
Measure the voltage at the fuel pump relay as
shown.
A8887A

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD211 POWER SUPPLY CHECK TO F.P. RELAY

(ALL TYPES)

Red No ~ REPAIR wire from fuel
Disconnect fuel pump relay. pump relay to EEC
power relay.
Key On, Engine Off.
DVOM on 20 volt scale. Yellow No ~ GO to IEFD221.
Measure the voltage on the red, and black/yellow
or yellow wires of the fuel pump relay connector Black/yellow ~ REPAIR black/yellow
as shown. No wire from Power
Distribution Box to Fuel
Is the voltage on these wires greater than 10.5 Pump' Relay and/or
YO Its? REPLACE 30 amp high
current fuse in Power
~4
Distribution Box
(position no. 1).
--------~ ~ A8"~"
EFD22] VOLTAGE CHECK AT PIN 1 OF EEC-IV

(ALL TYPES)
Key Off. Yes ~ REPAIR wire from fuel

pump relay to
Battery fully charged. battery (+).
Remove EEC-IV processor.
Install EEC-IV breakout box, Rotunda Tool Number
No ~ GO to Quick Test,
Section 14.
T83L-50-EEC:'IV or EEC-IV Monitor, Rotunda Tool
Number 007-00018.
Measure the voltage at Pin 1 of the breakout box,
or:
With EEC-IV Monitor install the appropriate overlay
according to engine and year.
Place selector switch "A" on the arrow that
points at selector switch "B". Place selector
switch 8 on KAPWR1. Turn EEC-IV Monitor power
on, read the voltage of pin 1 on the LCD display.

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD231 FUEL PUMP RELAY OPERATION CHECK

I (ALL TYPES)
Remove relay from vehicle. Yes ~ GO to IEFD241.

Connect a +12v supply to terminal "C" as
shown. No ~ .REPLACE fuel pur:np
relay.
Ground terminal "0" as shown.
Measure the resistance between terminals "A"
and "B" as shown.
Is the resistance lower than 1 ohm with the
power applied and greater than 10,000 ohms
with power removed from terminal "e"?
.' B c::J
~.
- ~ =A ~
. c + -
AS,,9-A
EFD241 VOLTAGE CHECK AT PIN 22 (ALL TYPES)
Key Off. Yes. ~ GO to Quick Test,

Section 14. .
Remove EEC-IV processor. No ~ GO to IEFD251.
Install breakout box, Rotunda Tool Number
T83L-50-EEC-IV, or EEC-IV Monitor, Rotunda Tool
Number 007-00018 or equivalent.
Key On, Engine Off.
Measure the voltage on Pin 22. of the breakout
box,
or:
With the EEC-IV Monitor, install the appropriate
overlay according to engine size and year. Place :
selector switch "A" on Pin 22, "FP", turn EEC-IV
Monitor power on and read voltage on Pin 22
from LCD readout.
Is voltage greater tha.n 10.5 volts?

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD2S1 VOLTAGE CHECK AT T/LG WIRE ON VIP

I (ALL TYPES)
Key Off. Yes ~ REPAIR Tan/Light

Green wire from EEC-
Battery fully charged. IV to fuel pump relay.
EEC-IV processor disconnected.
No ~ REPAIR Tan/Light
Key On, Engine Off. Green wire from fuel
DVOM ohm 20 volt scale. pump relay to EEC-IV
and from fuel pump
Measure the voltage on the fuel pump lead of the relay to VIP connector.
VIP Self Test connector as shown.
Is voltage above 10.5 volts?
~
~~'-
~ --
A889D-A
EFD261 FUEL PUMP LOW VOLTAGE CHECK

I (All TYPES)
Ground the FP lead of the Self Test connector Yes ~ GO to IEFD271.

using a jumper, as in Test Step IEFD2\ .
Connect the DVOM at the high-pressure fuel No ~ GO to IEFD31.
pump terminal (PK/BK).
Is the voltage at the fuel pump within 0.5 volt
of the battery?
EFD271 HIGH-PRESSURE FUEL FILTER CONDITION

I CHECK (ALL TYPES)
Observe Warning-Instructions to avoid fuel spillage Yes ~ For CFI systems: GO

and injury. to IEFD51J. For EFt
systems: GO to
Check the condition of the high-pressure fuel filter IEFD2SI.
and check the customers service records versus
the maintenance schedule.
No ~ SERVICE the filter(s)
Types 2 and 3 systems, check also the condition and RERUN test
of the fuel filter contained in the in-line reservoir, IEFD21.
if so equipped.
Is the fuel filter free of contamination and
blockage?

ALL RIGHTS RESERVED
~Iectric
Fuel Delivery Systems:
EFD
System Diagnosis
EFD28 PRESSURE REGULATOR DIAPHRAGM

CONDITION CHECK (TYPES 1, 2, 3, 4)

Connect the Fuel Pressure Test Kit at the
Schrader fitting on the rail. Observe Warning- No REPLACE the pressure
regulator and RERUN
Instructions to avoid fuel spillage and injury.
test IEFD21 .
Start engine and run for 10 seconds.
Stop engine and wait 10 seconds.
Start engine and run for 10 seconds.
Stop engine and remove the vacuum hose from
the pressure regulator.
Examine the vacuum port in the pressure
regulator for evidence of fuel leakage through the
diaphragm.
Is the vacuum port free of any fuel?
VACUUM
HOSE
VACUUM
PORT
PRESSURE
REGULATOR
A8891-A

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD291 PRESSURE REGULATOR FUEL PRESSURE

LEAKDOWN CHECK (ALL TYPES)
With the Fuel Pressure Test Kit still installed on No ~ GO to IEFD331.

the engine, run the engine for 30 seconds
minimum. Yes ~ GO to IEFD30\.
Stop the engine and observe the fuel pressure.
Does fuel pressure drop 5 psi (34 kPa)
maximum after 60 seconds?
EFD301 CHECK FUEL PUMP CHECK VALVE FOR

LEAKDOWN
Fuel Pressure Test Kit installed. Yes ~ For Types 2, 3, and 4:

REPLACE high
Disconnect and plug fuel return line at the engine. pressure fuel pump.
Run engine until normal fuel pressure is achieved. REMOVE fuel pressure
test kit. RECONNECT
Engine off, observe fuel pressure gauge. fuel return line.
Is fuel pressure drop greater than 5 psi (34
kPa) after 30 seconds? For Type 1:
REPLACE fuel sender/
pump assembly.
REMOVE fuel pressure
test kit. RECONNECT
fuel return line.
For Typ-e 5:
GO to IEFD31 I.
No ~ REPLACE fuel pressure

regulator. REMOVE fuel
pressure test kit.
RECONNECT fuel
return line.
EFD311 CHECK REAR TANK IN-TANK-RESERVOIR (ITR)
Fuel return line connected. Yes ~ REPLACE rear tank

ITR. REMOVE fuel
Remove the fuel supply line from the sender port
of the front tank and install fuel pressure gauge pressureH
RERUN EFD2 .
to the fuel line.
Move the tank selector to REAR position. No ~ REMOVE fuel pressure
Key ON, engine OFF. gauge. RECONNECT
fuel supply line to front
Wait till fuel pump stops (approximately 1 second). tank. GO to IEFD32 I.
Key off, observe fuel pressure.
Does fuel pressure drop?

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD32 CHECK FRONT TANK IN-TANK-RESERVOIR

(ITR)
Remove the fuel supply line from the sender port Yes REPLACE front tank
of the rear tank and install fuel pressure to the ITR. REMOVE fuel
fuel line. pressure~.
RERUN~.
Move the tank selector to FRONT position.
Key On, Engine Off. No REMOVE fuel pressure
Wait until fuel pump stops (approximately 1 gauge. RECONNECT
second). fuel supply line to rear
tank. GO to IEFD33 I.
Key Off, observe fuel pressure.
EFD33 PRESSURE REGULATOR VALVE SEAT

LEAKAGE CHECK (ALL TYPES)
Observe the Warning-Instructions to avoid fuel Yes ~ REPLACE the

spillage and injury. regUla/or. RERUN test
EFD2 .
Remove the fuel pressure regulator.
Inspect the O-ring and the gasket and mounting No GO to IEFD341.
surfaces for cracks, cuts or other defects that
may affect sealing.
Connect the vacuum tester to the fuel return tube
(shown below) and apply a 20 in-Hg vacuum.
Verify whether the vacuum retention meets
specification of 10 in-Hg maximum loss of vacuum
within 10 seconds.
Does the vacuum drop below 10 in-Hg with 10
seconds?
ENGINE VACUUM
REFERENCE TUBE
SPRING SPRING
SEAT
FUEL
FILTER
SCREEN
MOUNTING
PLATE
lkt1~iin~~rU~-- HOUSING
LOWER
O-RING 'l..!J11"+--- FUEL OUTLET

GROOVE TUBE (RETURN)
FUEL INLET TUBE
(SUPPLY) A12772A

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD341 FUEL SYSTEM LEAKAGE RE-CHECK

(ALL TYPES)
If it is necessary to disconnect any fuel lines, Yes ~ FO~ and 5, GO

observe the "Notes, Cautions and Warnings" to to EFD36 .
avoid fuel spillage and injury.
All other types, GO to
Reinspect the complete fuel delivery system, IEFD3SI.
components and lines for fuel leakage, pinching or
kinking that may cause low fuel pressure, as
evidenced by fuel odor, spillage, stains or damage
No ~ REPAIR or REPLACE
components as
caused by accident or collision. required. RERUN test
Is the fuel delivery system free of any step IEFD21 .
apparent defects that may cause low fuel
pressure?
EFD351 LOW PRESSURE (IN-TANK) FUEL PUMP FLOW

CHECK (TYPES 2, 3, 4)
Observe the "Notes, Cautions and Warnings" to Yes ~ GO to IEFD371 ..

Connect a jumper to the FP lead of the Self-Test No ~ pUlP no, running GO
connector and long enough to reach the work to EFD6 . Flow does
area under the vehicle when it is raised. not meet specification.
SERVICE pump inlet
Key On, Engine Off. filter or REPLACE
pump as required.
Raise vehicle on a hoist and bring the test lead RERUN test step
to a convenient point for grounding. IEFD21. .
Disconnect the pump pressure line at the reservoir
inlet fitting and place it in a measuring vessel of
at least one quart capacity.
Ground the test lead, verify that the pump is
running, using a stethoscope if necessary, and
that the pump flow meets specification.
Fuel flow specification:
180 m1 (6 oz) per 5 seconds..
Does the pump flow meet the specification?

ALL RIGHTS RESERVED
Fuel Delivery Systems

EFD
.System Diagnosis
EFD361 HIGH-PRESSURE (IN-TANK) FUEL PUMP FLOW

CHECK (TYPE 1 AND 5)
Observe the "Notes, Cautions and Warnings" to Yes ~ GO to IEFD37 I.

Disconnect the fuel return line at the fuel rail and No ~ SERVICE pump inlet
connect the fuel pressure testing kit. screen and rerun test.
REPLACE pump as
Provide a measuring vessel (1 quart capacity) and required. RERUN test
overflow vessel for measuring fuel flow through step IEFD21 .
the test kit.
Connect a jumper to the FP lead of the Self-Test
connector.
Key On, Engine Off.
Ground the jumper to run the fuel pump.
Collect the fuel flow into the measuring vessel for
15 seconds.
Is the fuel flow approximately 250 ml (8.3 oz)
per 15 seconds?
EFD371 HIGH-PRESSURE PUMP CHECK VALVE

LEAKDOWN CHECK (ALL TYPES)
Observe the Notes, Cautions and Warnings" to Yes ~ If leakdown rate OK.
FO~ and 5, GO
Connect the fuel pressure test kit at the fuel to EFD47 .
pressure test point.
All other types, GO to
Connect a jumper to the FP lead of the Self-Test IEFD401.
connector.
Key On, Engine Off. No ~ REPLACE pump.
RERUN test step
Ground the test lead using the jumper wire to ru':l
IEFD21.
the fuel pump.
Run the. fuel pump for 30 seconds minimum.
Remove the test lead ground and' note fuel
pressure on the gauge.
Verify whether the fuel pressure remains within
the specified 2 psi for 3 minutes after the test
lead is ungrounded.
Does the fuel pressure remain within 2 psi for
3 minutes after the test lead is ungrounded?

ALL RIGHTS RESERVED

EFD
System Diagnosis
_,I,
, "
TEST.. STEP RESULT ~ ACTION TO TAKE
EFD381 PRESSURE REGULATOR CHECK FOR HIGH

PRESSURE CAUSES (ALL TYPES)
Observe the "Notes, Cautions and Warnings" to Yes ~ REPLACE the regulator
avoid fuel spillage and injury. with a known good
regulator. RERUN test
Check leaks in the engine vacuum system due to step IEFD21. If
loose or mis-threaded fittings, cracks, cuts, pressure still high, GO
pinches, or kinks in vacuum lines, or blockages to IEFD391.
that could cause insufficient vacuum to properly
control the pressure regulator. No ~ REPAIR or REPLACE
Check the pressure regulator housing for damage damaged components
or dents that could cause a higher spring loao on as required. RERUN
test step IEFD21 .
the pressure regulator diaphragm.
Proceed with above
Check the integrity of the pressure regulator Action for "yes" result.
diaphragm per, the procedure of test step
IEFD2SI.
Is the fuel system free of defects that could
cause the pressure regulator to produce
excessive fuel injection pressure? (Refer to
Fuel pressure Specification In this Section).
'EFD391 FUEL RETURN SYSTEM CHECK FOR HIGH

PRESSURE CAUSES (TYPES) .
Observe the "Notes, Cautions and Warnings" to Yes ~ ~e 1 or 5, GO to

avoid fuel spillage and injury. EFD50 .
Remove the fuel return line at the pressure All other types, GO to
regulator and at the fuel tank(~). IEFD40I,.
Provide a suitable fuel receptacle at the tank
end(s) of the return lines to avoid fuel spillage. No ~ REPAIR defects,
CLEAN or REPLACE
Check the fuel return system(s) for restriction due faulty components as
to blockage,' kinking, or pinching by blowing required to remove the
through it with 5-1 0 psi regulated shop air. If the causes of high
system is Type 3 or 4 (dual tanks) switch the fuel pressure. PROCEED
selector switch so as to check both return lines. with Action for above
"yes" result.
Is the fuel return system free of any
restriction that could cause excessive fuel
injection pressure?
;
. ,

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD40 FUEL RESERVOIR ANTI-SIPHON VALVE '.

FUNCTION CHECK (TYPES 2, 3, 4)
This test step applies only to Light Truck fuel Yes ~2GOto
systems, types 2, 3, and 4 having the in-line ~.
reservoir.
~e3GOto
Observe the "Notes, Cautions and Warnings" to LmM!.J .
avoid fuel spillag and injury.
~4GOto
Disconnect the fuel supply line entering the ~.
reservoir:
For type 2 - from the tank No REPLACE the reservoir.
For type 3 - from the electric selector valve
For type 4 - from the rear tank
Selector switch in rear tank position (for type 4
system).
Connect the vacuum tester to the same reservoir
fuel supply nipple on the reservoir.
Apply a 10 in-Hg vacuum maximum to the fuel
supply nipple and observe the vacuum gauge.
i CAUTION-l
Any vacuum higher than 10 In-Hg may rupture
the diaphragm of the type 4 system reservoir.
Does the anti-siphon valve retain a 10 In-Hg
vacuum?
~-~ DISCONNECT AND

APPLY VACUUM
AT NIPPLE
TYPES 2 AND 3 - Fuel Reservoir TYPE 4 Fuel Reservoir Allt3-A

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD41 ELECTRIC SELECTOR VALVE FUNCTION

CHECK (TYPE 3)
Observe "Notes, Cautions and Warnings" to avoid Yes ~ GO to IEFD471.

fuel spillage and injury.
i CAUTION! No ~ GO to IEFD111.
To avoid fuel spillage when the selector switch

Is moved from one tank to the other, disconnect
the electrical connections at both In-tank fuel
pumps.
Disconnect all fuel supply lines (3) and return
lines (3) from the selector valve.
Prepare two lengths of test hose, fitted with Quick
Connectors to fit the selector valve nipples (to
avoid nipple damage), one for the supply side
nipples, and the other for the smaller return
nipples.
Using shop air regulated to 3-5 psi, connect the
test hoses to the engine supply and return
nipples, check the airflow paths when the selector
switch is moved from rear to front tank and vice-
versa, and verify that the selector valve functions
correctly.
Does the selector valve function correctly?
R=~~
SUPPLY
FRONT
REAR
SUPPLY
*
J.'
REAR
RETURN
SUPPLY
, AIR OUT A8894A

ALL RIGHTS RESERVED

EFD
System Diagnosis
TEST STEP RESULT . ACTION TO TAKE
EFD42 MECHANICAL SELECTOR VALVE/RESERVOIR

CHECK (TYPE 4)
For test steps EFD42 and 43. Yes ~ GO to IEFD431.
i :~AUTION 1 No Verify the valve is not

To avoid fuel spillage with the fuel lines in a neutral position.
disconnected, disconnect the electric connectors
at both in-tank fuel pumps.
The following test steps (EFD42 and 43) are
. required for checking correct function of the
mechanical selector valve which is integral with
the 6 nipple reservoir. The valve is not
serviceable.
Remove lines from valve, noting position of lines
for correct reinstallation.
Provide test hoses as described for test step
IEFD3S1 .to avoid nipple damage.
Provide shop air reduced to 3-5 PSI AND
REGULATED. Air pressure of 2 psi will operate
the valve, but PRESSURE GREATER THAN 5 PSI
MAY RUPTURE THE INTERNAL DIAPHRAGM.
Apply 3-5 psi air pressure to engine (front) side
return (smaller size) nipple, and check whether air
exits from either fuel return port on the rear (tank)
side of the unit.
Does air exit from either of the tank side
return ports?
NOTE: FLOW TO UNDER SIDE OF NOTE: FLOW TO TOP OF

DIAPHRAGM PUSHES DIAPHRAGM DIAPHRAGM PUSHES DIAPHRAGM
UP TO CLOSE FRONT TANK DOWN TO CLOSE REAR TANK \ .
SUPPLV AND RETURN PDRrS ~FRONTTANKSUPPLV
SUPPLY AND RETURN PORTS
(OUT)
(IN)
0.5 PSI ANTISIPHON VALVE 20 PSI DIVERTER VALVE ./ 20 PSI DIVERTER VALVE
REAR TANK FLOW FRONT OF VEHICLE
Notes In parentheses are for test purposes only. . / FRONT TANK FLOW A8895B

ALL RIGHTS RESERVED

EFD
System Diagnosis

RESET VALVE (TYPE 4)
Block fuel supply port (larger nipple) on engine Yes GO to IEFD441.

side of unit.
Apply 3-5 psi air pressure to one (F) and then No REPLACE the
Mechanical Selector
the other (R) tank side supply ports until a
Valve Reservoir (valves'
clicking sound is heard or felt, indicating a reset. stUCk).
Remove air from supply port, apply it to the
engine side return port and check whether air
exits from the tank side return port corresponding
to the final supply port after click.
Does air exit only from the correct
(corresponding) tank side return port?
NOTE: FLOW TO TOP OF

NOTE: FLOW TO UNDER SIDE OF
DIAPHRAGM PUSHES DIAPHRAGM
DIAPHRAGM PUSHES DIAPHRAGM
DOWN TO CLOSE REAR TANK
UP TO CLOSE FRONT TANK
REAR TANK SUPPLY SUPPLY AND RETURN PORTS
SUPPLY AND RETURN PORTS
ENGINE RETURN
ENGINE RETURN
(CHECK
AIR OUT)
(F)
0.5 PSI ANTISIPHON 20 PSI DIVERTER VALVE / 0.5 PSI ANTI-SIPHON VALVE
VALVE FRONT OF VEHICLE
REAR TANK FLOW
Notes In parentheses are for test purposes only / FRONT TANK FLOW A8896-A

ALL RIGHTS RESERVED

EFD
System Diagnosis

SWITCHING ACTION CHECK (TYPE 4)
Block engine side supply port. Yes ~ GO to IEFD4SI.

Apply 3-5 psi air pressure to the other tank side
supply port from the preceding test step~ and note No ~ RECHECK test step
a clicking sound when the valve switches to the IEFD44 I front and rear
tank ports alternately.. If
new selected tank supply pressure. unit still fails test,
Remove 3-5 psi air pressure from the supply port, REPLACE the
apply it to the corresponding tank side return port Mechanical Selector
and note whether air exits from the engine side Valve Reservoir.
return port.
Does air exit from the engine side return port?
NOTE: FLOW TO UNDER SIDE OF NOTE: FLOW TO TOP OF

DIAPHRAGM PUSHES DIAPHRAGM DIAPHRAGM PUSHES DIAPHRAGM
UP TO CLOSE FRONT TANK DOWN TO CLOSE REAR TANK
SUPPLY AND RETURN PORTS SUPPLY AND RETURN PORTS
(CHECK
AIR IN)
0.5 PSI ANTISIPHON VALVE 20 PSI DIVERTER VALVE

REAR TANK FLOW
Notes In parentheses are for test purposes only
--- ---
FRONT OF VEHICLE
FRONT TANK FLOW A8897A

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD4S1 MECHANICAL SELECTOR VALVE/RESERVOIR

SUPPLY SIDE LEAKAGE CHECK (TYPE 4)
Remove any previously applied blockages. Yes ~ GO to IEFD461.

Apply 3-5 psi pressure to the engine side supply
port and note which tank side supply port is No ~ REPLACE unit.
open.
Block the open tank side supply port.
Connect the vacuum and pressure tester to the
closed tank side supply port and note any
pressure on the gauge with air pressure applied.
Is the supply side free of any internal valve
leakage (zero reading on pressure gauge)?

RETURN SIDE LEAKAGE CHECK (TYPE 4)
Remove any previously applied blockages. Yes ~ GO to IEFD471.

Apply 3-5 psi pressure to the engine side return
port and note which tank side return port is open. No ~ REPLACE the selector
valve.
Block the open tank side return port.
Connect the vacuum and pressure tester to the
closed tank side return port and note any
pressure on the gauge with air pressure applied.
Is the return side free of any internal valve
leakage (zero reading on pressure gauge)?
EFD471 FUEL INJECTOR FUNCTION CHECK

(ALL TYPES)
With the engine warmed and idling (or cranking it Yes ~ GO to IEFD501.
if does not start) and using a mechanics'
stethoscope or equivalent, listen for regularly No ~ GO to IEFD4S1 .
spaced operating sounds at each fuel injector.
Is operating sound present?

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD4S1 FUEL INJECTOR RESISTANCE CHECK

I (ALL TYPES)
Observe the "Notes, Cautions and Warnings" to Yes ~ GO to IEFD491.
avoid fuel spillage and injury. '
Remove the fuel injectors from the engine, if No ~ REPLACE the faulty
required. injectors, RERUN test
Check the electrical resistance of each injector, step IEFD47 I, and if
using the DVOM, refer to resistance chart. OK, GO to test step
Are all the Injectors within the resistance IEFD501.
specification?
PASSENGER CAR ENGINES

VALUES ARE IN OHMS
1.9L 1.9L/2.5L 2.3L 3.0L ALL OTHER
OHC ENGINES
EFI CFI ONLY EFI WITH EFI
2.0 1.0 15.0 13.0
TO TO TO TO
2.7 2.0 18.0 16.0
LIGHT TRUCK ENGINES

VALUES ARE IN OHMS
2.31/3.0L ALL OTHER
EFI ENGINES WITH EFI
15.0 13.0
TO TO
18.0 16.0

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD491 FUEL INJECTOR ELECTRICAL SIGNAL CHECK

(ALL TYPES)
Check the electrical continuity of the injector Yes ~ GO to IEFD501.

harness between each injector and the ECA as
follows: No ~ CHECK for 12 volts at
Disconnect the injector lead and insert the each injector lead.
continuity checker No. FA-407 (from the Rotunda REPAIR or REPLACE
Fuel Injector Tester/Cleaner) into the injector lead leads as required.
plug. REFER to Quick Test,
Section 14 of this
Start the engine. manual.
Observe whether the continuity checker blinks
(showing a completed circuit for the injector being
tested).
Repeat the check for each injector.
Do all injector circuit leads show continuity?
EFD501 FUEL INJECTOR FLOW AND LEAKAGE CHECK

(ALL TYPES) EFI ONLY
Observe the "Notes, Cautions and Warnings" to Yes ~ GO to Section 2.

Using the Fuel Injector Tester Cleaner as No ~ REPLACE the damaged
described in Section 4 of this manual and injectors as required.
accompanying instruction, clean, test and reclean RERUN test IEFD50 I.
as required, the fuel injectors and verify that the
flow rate for the injector group is within
specification, using the color range on the Tester
flow meter corresponding to the injector top color.
Verify the injector color for the engine by the
Injector Application chart, Section 4 of this
manual.
With the Tester/Cleaner still installed on the fuel
system note any significant pressure loss due to
injector leakage when the tester pump is turned
off.
Check the fuel injectors individually for leakage as
required using the Injector Bench Fixture and the
Fuel Injector Bench Testing Procedure associated
with the Rotunda Tester/Cleaner as required and
verify that each injector leakage rate is within
specification (1 drop/min. maximum).
Is the flow rate for the injector group and the
leakage rate for individual injectors within
specification?

ALL RIGHTS RESERVED

EFD
System Diagnosis
Fuel Pressure Regulator Description for CFI System

The Pressure Regulator is integral to the fuel charging main body and is located near the rear
of the air horn. It is located so as to nullify the effects of supply line pressure drops. Its
design is such that it is not sensitive to back pressure in the return line to the tank.
One function of the Pressure Regulator is to maintain fuel supply pressure upon engine and
fuel pump shutdown. The regulator functions as a downstream check valve and traps the fuel
between itself and the fuel pump. The maintenance of fuel pressure upon engine shutdown
precludes fuel line vapor formation and' allows for rapid restarts and for stable idle operation
immediately thereafter.
EFD511 CHECK FUEL PRESSURE
Disconnect electrical connection to inertia switch. Yes ~ GO to IEFD521.

Crank engine for five seconds to reduce fuel
pressure in the fuel charging system. No ~ GO to IEFD34 I. Also
REFER to Fuel/Engine
Install fuel pressure gauge.
Shop Manual Group.
Reconnect electrical connection to inertia switch.
Start and run engine.
Stabilize fuel pressure.
Key Off.
EFD521 CHECK VACUUM BLEED DOWN
Remove fuel inlet and outlet lines at fuel charging Yes ~ GO to IEFD531.
assembly.
Connect hand held vacuum pump to the fuel No ~ Injector/O-Ring
charging assembly fuel inlet side. regulator seat/valve
Apply 15-20 in-Hg vacuum. tystem 10K. GO to
EFD34 .
Vacuum should not drop more than 10 'in-Hg in
10 seconds.
Is vacuum drop greater than 10 in-Hg in 10
seconds?
EFD531 CHECK VACUUM BLEED DOWN
Refer to Test Step IEFD52 I. Yes ~ GO to IEFD541.

Cap/plug the fuel outlet line.
Repeat Test Step IEFD52 I.
No ~ SERVICE fuel pressure
regulator. REFER to
Is vacuum drop greater than 10 in-Hg in 10 Fuel/Engine Shop
seconds? Manual Group.

ALL RIGHTS RESERVED

EFD
System Diagnosis
EFD541 CHECK INJECTOR
With the injector in the fuel charging assembly: Yes ~ REPLACE the injector
Plug the injector tip outlet with finger. O-Rings - 2. REPEAT
test step IEFD54 I.
Repeat Test Step IEFD52 I.
Is vacuum drop greater than 10 in-Hg in 10
seconds? No ~ REPLACE injector.
REFER to Fuel/Engine
Shop Manual Group.

ALL RIGHTS RESERVED
SECTION 12
6.1L/7.0L Heavy Duty Truck-

"CHECK ENGINE" Light
Contents
Vehicle Application, Description and Operation 12-1
When to Use This Diagnostic Procedure 12-1
System Schematic 12-2

ALL RIGHTS RESERVED
6.1L/7.0L Heavy Duty Truck- "CHECK ENGINE" Light 12-1
System Description
VEHICLE APPLICATION
NOTE: This applies to only 1990 49 State 6.1 Land 7.0L heavy duty trucks (gasoline
engines only). All other vehicle applications with "CHECK ENGINE" Light
concerns, go to Quick Test, Section 14.
DESCRIPTION AND OPERATION
The "CHECK ENGINE" Light (CEL) System on the 6.1 land 7.0l heavy duty trucks consists
of an instrument panel mounted amber lens with the words "CHECK ENGINE" printed on it. It
is electrically connected to an Emission Maintenance Warning (EMW) module located under
the instrument panel. The purpose of the system is to alert the customer that 60,000 mile
emission system maintenance is required on the vehicle. Specific emission system maintenance
requirements are shown in the vehicle Owner Guide (Medium and Heavy Duty Truck).
The EMW module actually measures accumulated vehicle ignition Key On time and is designed
to continuously close an electrical circuit to the CEl after 2000 hours of vehicle operation.
Assuming an average vehicle speed of 30 mph, the 2000 hours equates to 60,000 miles of
vehicle operation. Actual vehicle mileage intervals will vary considerably as individual driving
habits vary.
Note that when the ignition key is initially placed in the ON position, the EMW module will
activate the CEl for 2 to 5 seconds to indicate proper function of the system. When
approximately 60,000 miles of vehicle operation is reached, the CEl will remain on
continuously, indicating that emission system maintenance is required. After the vehicle's
emission system maintenance has been performed, the technician should reset the EMW
module for another 60,000 mile period.
WHEN TO USE THIS DIAGNOSTIC PROCEDURE
Emission maintenance should be performed if the "CHECK ENGINE" Light is on

continuously and either of the following is true:
Mileage is between 45,000 and 75,000 miles with no previous emission maintenance.
Mileage is greater than 105,000 miles.
Use this procedure only when the specified mileage does not apply or if the EMW
module cannot be reset after emission maintenance is completed.

ALL RIGHTS RESERVED
12-2 6.1L/7.0L Heavy Duty Truck- "CHECK ENGINE" Light
System Description
SYSTEM SCHEMATIC
6.1 land 7.0l Heavy Duty Trucks "CHECK ENGINE" Light (CEl)
IGNITION "KEY ON"/RUN MODE
*194 BULB
...-.--.... - KEY POWER..-----1
~
VOUT
~
_----t- GND
~
_ CHASSIS GROUND
1
LOOKING INTO
MODULE
E
~ 'II
ORIENTATION TAB
A8334-C
NOTE: All other engine/vehicle applications with "CHECK ENGINE" Light concerns, go
to Quick Test, Section 14.

ALL RIGHTS RESERVED
6.1l/7.0l Heavy Duty Truck- "CHECK ENGINE" light 123
Pinpoint
ISystem Diagnosis Test
CE
NOTE: This applies to only 1990 49 State, 6.1 land 7.0l heavy duty trucks (gasoline
engines only). All other vehicle applications with "CHECK ENGINE" light
CE1 IVERIFY "CHECK ENGINE" LIGHT (CEL)

STATUS
Key off. Yes ~ System OK.

Turn key to ON position.
No ~ GO to ICE21.
Does CEl come on for 25 seconds and go
off?
CE2 I CHECK EMW MODULE POWER
EMW module connected. Yes ~ GO to ICE31.

Key on, engine off.
No ~ SERVICE open in KEY
DVOM, Rotunda 007-00001 or equivalent~ on 20 POWER or GND circuit.
volt scale.
Measure voltage between KEY POWER and GND
circuits at the EMW module.
Is voltage greater than 10.5 volts?
CE3 I CHECK EMW MODULE OUTPUT
Key off. Yes ~ GO to ICE41.

EMW module connected.
No ~ GO to ICESI.
Key on, engine off.
Measure voltage between KEY POWER and
VOUT circuits at the EMW module.
Is voltage greater than 10.5 volts for 25
seconds and then drops to less than 4.0
volts?

ALL RIGHTS RESERVED
.12-4 6.1L/7.0L Heavy Duty Truck- "CHECK ENGINE" Light
Pinpoint
ISystem Diagnosis Test
CE
CE41 CHECK CONTINUITY OF KEY POWER

AND VOUT CIRCUITS
Key off. Yes ~ REPLACE bulb.

RECONNECT EMW
Disconnect EMW module. module. REPEAT
DVOM 200 ohm scale. ICE11.
Measure resistance between KEY POWER circuit

at the EMW module vehicle harness connector
No ~ SERVICE open circuit.
RECONNECT EMW
and CEl bulb. module. REPEAT
Measure resistance between VOUT circuit at the ICE11.
EMW module vehicle harness connector and CEl
bulb.
Is each resistance less than 5 ohms?
CEsl CHECK VOUT CIRCUIT FOR SHORTS TO

GROUND OR POWER
Key off. Yes ~ RECONNECT all

components. ~t is
Disconnect EMW module. always on in CE1 ,
Disconnect CEl bulb. GO to Table 2. ~t
is always off in CE1 ,
DVOM on 200,000 ohm scale. GO to Table 1.
Measure resistance between VOUT circuit at the
EMW module vehicle harness connector and No ~ SERVICE short circuit.
battery negative post and battery positive post. RECONNECT all
components. REPEAT
Is each resistance greater than 10,000 ohms? ICE11.

ALL RIGHTS RESERVED
6.1U7.0L Heavy Duty Truck- "CHECK ENGINE" Light 12-5
____S_y_s_te_m
__D_ia_g_D_o_S_i_S 1 Table 1
"CHECK ENGINE" LIGHT NEVER ON:
NOTE: This applies to only 1990 49 state 6.1 Land 7.0L heavy duty trucks (gasoline
SITUATION ACTION TO TAKE
to 15,000 Miles REPLACE EMW module with 2000 hour "time out" module.
No emission maintenance required.
15,000 to 45,000 Miles REPLACE EMW module with pretimed 1000 hour module.
45,000 to 75,000 Miles (no previous REPLACE EMW module with 2000 hour "time out" module.
emission maintenance was done). Perform required emission maintenance.
60,000 to 75,000 Miles (previous REPLACE EMW module with 2000 hour "time out" module.
emission maintenance has been done). No emission maintenance required.
Greater than 105,000 Miles REPLACE EMW module with 2000 hour "time out" module.
Perform required emission maintenance.

ALL RIGHTS RESERVED
12-6 6.1L/7.0L Heavy Duty Truck- "CHECK ENGINE" Light
__S_y_s_te_m_D_ia_g_D_o_S_iS 1 Table 2
"CHECK ENGINE" LIGHT ALWAYS ON:
NOTE: This applies to only 1990 49 state 6.1 Land 7.0L heavy duty trucks (gasoline
SITUATION ACTION TO TAKE
o to 15,000 Miles RESET EMW module*. No emission maintenance required.

15,000 to 45,000 Miles RELACE EMW module with pretimed 1000 hour module. No
emission maitenance required.
45,000 to 75,000 Miles (no previous RESET EMW module*. Perform emission maintenance.
emission maintenance was done).
60,000 to 75,000 miles (previous RESET EMW module*. No emission maintenance required.
emission maintenance has been done).
Greater than 105,000 Miles RESET EMW module*. Perform emission maintenance.
*Refer to Table 3 for reset procedure. If not resettable type module, replace with 2000
hour "time out" EMW module. If any module cannot be reset as described In Table 3,
replace with a 2000 hour "time out" EMW module.

ALL RIGHTS RESERVED
6.1L/7.0L Heavy Duty Truck- "CHECK ENGINE" Light 127
System Diagnosis Table. 3
RESET PROCEDURE:
The timer may be reset either before or after the timeout period has been exceeded. The
procedure is the same for either condition.
Step 1
Turn the ignition switch to the OFF position.
Step 2
Lightly push the shank end of a No. 2 or 7/32 inch drill bit through the .2 inch diameter hole
with the sticker labeled RESET', lightly press down and hold. Go to Step 3.
I
Step. 3
Still pressing the drill bit down, turn the ignition switch to the RUN position. The GEL will then
light and should remain lit for as long as the drill bit is pressed down. Hold the drill bit down
for approximately five seconds. Go to Step 4.
Step 4
Remove the drill bit. The lamp should go out within approximately 2 to 5 seconds indicating a
reset has occurred. If the lamp does not go out then begin again with Step 1. Turn the
ignition switch to the OFF position and go to Step 5.
Step 5
Turn the ignition switch to the RUN position. The GEL will light for approximately 2 to 5
seconds and will then go out. This verifies that a proper reset of the EMW module has been
accomplished. If the GEL remains on, then the proper reset has not occurred and the reset
procedure should be repeated. Turn the ignition switch to the OFF position.

ALL RIGHTS RESERVED
SECTION 13
Ignition Systems, Timing

Procedures and Diagnosis
Contents
Ignition System Applications 13-1
TFI IGNITION SYSTEM:
Initial Timing Set Procedure 13-2
Spark Timing Advance - EEC-IV 13-4
Spark Timing Advance - Non EEC 13-7
Symptom Index 13-15
Ignition System Diagnostic Procedures - TFI 13-15
Part 1 (Secondary).............................................................. 13-16
Part 2 (Primary)
Duraspark II 13-24
TFI-IV : 13-42 .
TFI-IV With Computer Controlled Dwell (CCD) 13-42
TFI-IV Closed Bowl Distributor 13-55
Intermittent Diagnosis Procedure 13-72
DISTRIBUTORLESS IGNITION SYSTEM (DIS)
Ignition System Diagnostic Procedures (DIS)
2.3L EFi Truck (Dual Plug) 13-76
3.0L SHO SEFI and 3.8L SC SEFI 13-122
ELECTRONIC DISTRIBUTORLESS IGNITION SYSTEM (EDIS)
4.0L EFI Truck (EDIS) 13-165

ALL RIGHTS RESERVED
Ignition Systems, Timing Procedures and Diagnosis 13-1
Ignition System Applications
PASSENGER CAR ENGINES IGNITION SYSTEM
1.9/2.3L HSC/2.5L/5.0L TFI-IV I
2.3L OHC Mustang - 49 States TFI-IV

3.0L Taurus/Sable - 49 States TFI-IV
2.3L OHC Mustang - California TFI-IV with Computer Controlled
Dwell (CCD)
3.0L Taurus/Sable - California TFI-IV with Computer Controlled
Dwell (CCD)
3.0L Probe TFI-IV with Computer Controlled
Dwell (CCD)
*3.0L SHO Distributorless (DIS)
*3.8L SC Distributorless (DIS)
3.8L TFI-IV Closed Bowl Distributor
5.8L Duraspark II
TRUCK ENGINES IGNITION SYSTEM
*2:3L Distributorless (DIS)

2.9/3.0/4.9/5.0/5.8L TFI-IV
*4.0L Electronic Distributorless (EDIS)
7.0L Duraspark II
7.5L TFI-IV Closed Bowl Distributor
*Refer to the separate Distributorless Ignition Section for these applications.

ALL RIGHTS RESERVED
13-2 Ignition Systems, Timing Procedures and Diagnosis
Initial Timing Set Procedure
PRELIMINARY NOTE
The procedure described below for setting initial timing is to be used under normal
circumstances. If problems are encountered setting initial timing using this procedure,
the spark timing procedure that follows should be used to diagnose the problem.
Procedure Non-EEC EECIV

o Place transmission in PARK or NEUTRAL, A/C and heater in OFF position. X X
Remove vacuum hoses from the distributor vacuum advance connection at the
distributor and plug the hoses. X
Connect an inductive timing light, Rotunda 059-00006 or equivalent. X X
@ Connect a tachometer, Rotunda 059-00010 or equivalent. X
Disconnect the single wire in-line spout connector or remove the shorting bar from
the double wire spout connector. X
If the vehicle is equipped with a barometric pressure switch (-12A243-) disconnect
it from the ignition module and place a jumper wire across the pins at the ignition
module connector (yellow and black wires). X
CD Start the engine and allow it to warm up to operating temperature. X X
With engine at timing rpm if specified, check/adjust initial timing to specification. X X
Reconnect single wire in-line spout connector or reinstall the shorting bar on the .
double wire spout connector. Check timing advance to verify distributor is
advancing beyond the initial setting. If it is not, refer to Section 14 Quick Test 04. X
@ Remove test instruments. X X
~ Unplug and reconnect vacuum hoses. X
@ Remove jumper from ignition connector and reconnect if applicable. X

ALL RIGHTS RESERVED
SPARK'TIMING
ADVANCE

ALL RIGHTS RESERVED
134 Ignition Systems, Timing Procedures and Diagnosis
Spark Timing Advance

EEC-IV Equipped Vehicles
CHECKOUT
Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires
are properly routed and securely connected.
Examine all wiring harnesses and connectors for insulation damage, burned, overheated,
loose or broken conditions.
Be certain battery is fully charged.
All accessories should be off during diagnosis.
EQUIPMENT
Obtain the following test equipment or an equivalent:
Small straight pin.
Volt/Ohm Meter Rotunda 014-00407.
NOTES
This procedure is applicable to all EEC-IV equipped vehicles.
Spark Timing Advance is controlled by the EEC system. This procedure checks the capability
of the ignition module to receive the spark timing command from the EEC module.

ALL RIGHTS RESERVED
Ignition Systems, Timing Procedures and Diagnosis . 13-5
.Spark Timing Advance - ~EC Test 1
1. Key in OFF position. . Yes ~ TFI is OK. GO to EEC

Diagnosis, Section 14
2. Disconnect the pin in-lifle connector near the TFI Computed Timing.
module (SPOUT).
3. Attach the negative (-) VOM lead to the No ~ GO to Test 2.
distributor base.
4. Start the engine and measure the battery voltage
at idle.
5. Measure the voltage on the TFI module side of
the pin in-line connector.
6. Is the result between 30 percent and 60
percent of battery voltage?
DISTRIBUTOR ASSY
A9368-A

ALL RIGHTS RESERVED
Spark Timing Advance - EEC Test 2
1. Separate wiring harness connector from ignition Yes ~ REPLACE the TFI
module. Inspect for dirt, corrosion and damage. module.
NOTE: PUSH connector tabs to separate.
No ~ SERVICE the wiring
2. Using small straight pin inserted into connector between the pin in-line
terminal 5, measure resistance between the connector and the TFI
terminal and the TFI module side of the pin in- connector.
line connector.
3. Is the result less than 5 ohms?
IGNITION
A4----MODULE
CONNECTOR
TERMINAL
NO. 1 ~_--r.!!!!1:2
A9439-A

ALL RIGHTS RESERVED

Non-EEe Equipped Vehicles
CHECKOUT
Be certain battery is fully charged.
EQUIPMENT
Inductive Timing Light, Rotunda 059-00006.
Tachometer, Rotunda 099-00003.
Vacuum Gauge, Rotunda 059-00008.
NOTES
This procedure is not applicable to EEC-IV equipped vehicles.
This procedure checks the operation of the centrifugal and vacuum advance mechanisms in
the distributor. It is also to be used to check the operation of the retard feature of the
(-12A244-) Ignition Module.

ALL RIGHTS RESERVED
Spark Timing Advance - Non-EEC
STEP 1 I
Disconnect and plug distributor vacuum hose(s). ~ GO to Step 2.
Connect timing light and tachometer.
STEP 2 I
If Ignition Module (-12A244-) is used: ~ GO to Step 3.
Disconnect two wire connector (YELLOW and
BLACK wires).
Jumper pins in module connector.
If (-12A244-) Ignition Module not used. skip this
Step.
STEP 3 I
Start and warm-up engine. Yes ~ OK. GO to Step 4..
Check that engine speed is at or below timing
rpm.* No ~ RESET rpm below
timing rpm. GO to
Is engine speed at or below timing rpm*? Step 4.
* Refer to Vehicle Emission Control Information Decal.

ALL RIGHTS RESERVED
TEST STEP RESULT ~ ACTION TO' TAKE
STEP 4 I
Positive-Buy timing? Yes ~ GO to Step 5.
No ~ GO to Step 6.
STEP 5 I
Check initial timing. Yes ~ GO to Step 7.
NOTE: Record reading for later use.
No ~ RESET timing. .
Is timing within 4 degrees of required?* REMOVE or deface
positive buy label.
GO to Step 7.
STEP 6 I
Check initial timing. Yes ~ GO to Step 7.
NOTE: Record reading for later use.
No ~ .RESET timing.
Is timing within 2 degrees of requlred?*
GO to Step 7.
* Refer to Vehicle Emission Control Information Decal.

ALL RIGHTS RESERVED
TEST STEP RESULT ~. ACTION TO TAKE
STEP 7 I
Basic Part No. (-12A244-) on ignition module1 Yes ~ REMOVE jumper in two
wire connector.
RECONNECT two wire

connector.
GO to Step 8.
No ~ GO to Step 11.
STEP 8 I
Check initial timing at timing rpm. Yes ~ DISCONNECT two wire
connector (YELLOW
Is timing the same as Step 5 or 61 and BLACK wires) at
ignition module.
GO to Step 9.
NOTE: Engine may

die when connector
is separated due to
excessive spark
retard. If this
happens spark retard
operation is OK.
RECONNECT two wire
connector, GO to
Step 11.
No ~ REFER to the MCU

Diagnosis Manual then
return to Step 2.
STEP 9 I
Check initial timing at timing rpm. Yes ~ Retard operation OK.
Is timing retarded from Step 81
REMOVE vacuum
gauge and
RECONNECT vacuum
hose (if used).
GO to Step 11.
No ~ GO to Step 10.

ALL RIGHTS RESERVED
STEP 101
Substitute new ignition module. Yes ~ RETURN to Step 8.

Connect two wire (RED and WHITE wires) and NOTE: If Ignition
four wire connectors. module substitution
appears to correct
Jumper pins in two wire (YELLOW and BLACK
problem,
wires) connector. RECONNECT
Check initial timing at timing rpm. original module and
REPEAT this Step
Is. timing the same as Step 5 or 6? to verify service.
No ~ REPEAT Step 10.
STEP 11 1
Increase engine speed to 2,500 rpm. Yes ~ GO to Step 12.

Check spark timing.
No ~ REPLACE distributor.
Return to idle rpm.
REPEAT this Step.
NOTE: Refer to the Service Performance
Manual for total advance at 2,500
rpm/vacuum advance disconnected
under the correct engine calibration for
specification.
Is timing within specification?
STEP 121
Check initial timing at timing rpm. Yes ~ Distributor mechanical

advance mechanism
Is timing the same as Step 5 or 6? OK.
GO to Step 13.
No ~ REPLACE distributor.
RETURN to Step 11.

ALL RIGHTS RESERVED
STEP 131
Install distributor vacuum advance hose without Yes ~ Distributor vacuum

spark delay valve if used. advance mechanism
OK.
Increase engine speed to 2,500 rpm, hold for 60
seconds. REFER to Section 3.
CHECK operation of
Check spark timing. spark-delay valve if
Return to idle rpm. used.
NOTE: Refer to the Service Performance GO to Step 17.
Manual for total advance at 2,500
rpm/vacuum advance connected under
the correct engine calibration for
No ~ GO to Step 14.
specification.
STEP 141
Install vacuum gauge in vacuum advance hose, Yes ~ INSPECT diaphragm for
using tee connector ~ vacuum leaks and
stator assembly for
Increase engine speed to 2,500 rpm, hold for 60 sticking/binding.
seconds. SERVICE/REPLACE as
necessary.
Check for presence of vacuum.
Return to idle rpm. RETURN to Step 13.
Was a minimum of 51 kPa (15 In-Hg) vacuum
obtained? No ~ GO to Step 15.
STEP 151
Check engine for vacuum lockout devices. Yes ~ GO to Step 16.

(Refer to Vehicle Emission Control Information
Decal) No ~ SERVICE vacuum
source.
D08s engine have lockout devices?
RETURN to Step 13.

ALL RIGHTS RESERVED
TEST STEP RESULT ... ACTION TO TAKE
STEP 161
Disconnect and plug distributor vacuum advance Yes .- ... SERVICE vacuum
hose. source.
Attach vacuum hose between distributor vacuum DISCONNECT manifold

advance diaphragm connection and manifold vacuum.
vacuum.
REMOVE vacuum ,
Increase engine speed to 2,500 rpm. gauge and tee.
Check spark timing.
RETURN to Step 13.
Return to idle rpm.
NOTE: Refer to the Service Performance No . ... INSPECT diaphragm for
Manual for total advance at 2,500 leaks and stator
rpm/vacuum advance connected under assembly for sticking/
the correct engine calibration for binding.
SERVICE/REPLACE as
specification.
necessary.
DISCONNECT manifold
vacuum.
RECONNECT normal
vacuum source.
RETURN to Step 13.
STEP 17(
Does distributor have dual diaphragm? Yes ... GO to Step 18.
No ... Spark timing systems

OK.
.
ALL RIGHTS RESERVED
STEP 181
Disconnect and plug vacuum hose to vacuum Yes ~ Spark timing systems
advance connection on diaphragm. OK.
Connect vacuum hose to retard connection on RECONNECT vacuum

diaphragm. ,
hose to vacuum
advance connection.
Check spark timing at idle rpm.
Is timing retarded from Step 5 or 61 No ~ GO to Step .19.
STEP 191
Install vacuum gauge in vacuum hose to retard Yes ~ REPLACE distributor

connection on diaphragm. diaphragm assembly.
Check for presence of vacuum at idle rpm. RETURN to Step 18.
Is a minimum of 15 kPa (15 In-Hg) vacuum
obtained? No ~ SERVICE vacuum
source.
RETURN to St~p 18.

ALL RIGHTS RESERVED
Ignition Systems, Timing Procedures and Diagnosis 1315
Diagnostic Procedures
PRELIMINARY NOTES
The engine analyzer is used to diagnose problems in the secondary side of the ignition
system. This is covered in Part 1, which is common for all 1989 ignition systems (except
distributorless ignition).
For problems in the primary side of the ignition system, there is a separate Part 2 for each of
the three basic types of ignition systems.
;.
The beginning point for Ignition System Diagnosis is the Symptom Index. This will direct
you to the proper part for your engine symptom.
If after completing a Part 1 or Part 2 diagnosis and a problem has not been solved, the
problem is either an intermittent one or is not in the ignition system. If you suspect it to be
intermittent, refer to intermittent diagnosis. Otherwise return to the Diagnostic Routines,
(Section 2), for additional assistance. .
SYMPTOM INDEX
ENGINE SYMPTOM START AT
CRANKS NORMALLY BUT WON'T START PART 2

. STARTS NORMALLY BUT WON'T RUN (STALLS) PART 2
CRANKS NORMALLY BUT SLOW TO START PART 1
ROUGH IDLE PART 1
ENGINE MISS PART 1
POOR FUEL ECONOMY PART 1

ALL RIGHTS RESERVED
PART 1

ALL RIGHTS RESERVED
Preliminary Checkout & Equipment
CHECKOUT
Be certain the battery is fully charged.
EQUIPMENT
Spark Tester, Special Service Tool 081 P-6666-A. See NOTE.
Engine Analyzer, Rotunda 002-00373.
Volt/Ohm Meter, Rotunda 01400407.
NOTE
A spark plug with a broken side electrode is not sufficient to check for spark and may lead
to incorrect results.

ALL RIGHTS RESERVED
Ignition Coil Secondary Voltage Part 1 Test 1
Will engine start and run? Yes ~ Test Result OK.

GO to Part 1, Test 2.
No ~ INSPECT ignition coil

for damage, carbon
tracking.
MEASURE resistance
of ignition coil wire.
REPLACE if greater
than 7,000 ohms per
foot.

ALL RIGHTS RESERVED
ISecondary Display Part' 1 Test 2
NOTE: If this portion of the diagnostic procedure is to provide accurate results, it is

essential that the calibration of y~ur engine analyzer be maintained. Refer to
your equipment manual. If this is not available, an estimate of the calibration can be
made by connecting the spark tester (081 P-6666-A or equivalent) to a properly
operating ignition system and measuring the firing voltage of the spark tester only.
Do not Include the firing voltage of the rotor-to-cap gap. The spark tester firing
voltage should be approximately 28 KV.
1. Connect engine analyzer to view parade display

of ignition system secondary.
2. While slowly increasing engine rpm from idle to
2,000 rpm, compare engine analyzer display to
the following illustrations. The illustrations shown
are four cylinder but are typical for all engines.
3. Disconnect engine analyzer.

ALL RIGHTS RESERVED
Secondary Display - Continued Part 1 Test 2
The average ~ These are normal

value of spark values for a properly
FIRING VOLTAGE plug firing operating ignition
EVENNESS AVERAGE voltage: 15 KV system.
(HIGH TO LOW)_ ~
...... .r_ ~VO~GE or less with
evenness of
spark plug firing
vortage: 5 KV
or less
The average ~ Problems affecting all

value of spark cylinders:
plug firing
voltage: greater CHECK ignition coil
than 15 KV wire for proper
with evenness installation in coil and
of spark plug distributor cap.
firing voltage: 5
KV or less MEASURE resistance
REPLACE if greater
than 7,000 ohms per
foot.
Wide spark plug

gaps - all cylinders,
(usually from worn
electrodes due to high
mileage).
INSPECT cap and rotor

for problems causing
excessive cap-to-rotor
gap.

ALL RIGHTS RESERVED
Evenness of ~ Problems affecting

spark plug firing some cylinders:
voltage: greater
than 5 KV Wide spark plug gap(s)
or worn ~Iectrode(s).
Improperly installed
cap, adapter, or rotor.
Consistently ~ Spark plug wire(s) not

high spark plug firmly connected to
firing voltage in distributor cap or spark
one or more plug.
cylinders
Disconnected spark
plug wire(s).
Wide spark plug gap(s).
Open plllg wire(s). GO

to Part 1, Test 3.

ALL RIGHTS RESERVED
Consistently low .. Fouled spark plug(s).

spark plug firing
voltage or Narrow spark plug
sloping spark gap(s).
. FIRING VOLTAGE
line in one or
-------1-- more cylinders Spark plug wire(s)
grounding on engine.
Inspect for damage.
Carbon tracking in cap

and adapter.
i-LINE
Spark plug .. Ignition coil primary

firing voltage circuit reversed.
negative going CHECK wiring harness
for ignition coil primary
circuit. If OK,
REPLACE ignition coil.

ALL RIGHTS RESERVED
Spark Plug Wire Resistance Part 1 TestS
1. Remove distributor cap from distributor. Yes Spark plug wire

resistance OK.
2. Check for spark plug wires firmly seated on cap.
3. Disconnect spark plug end of suspect wire(s). No REPLACE spark plug
wire(s).
4. Measure resistance from terminal in cap to spark
plug terminal.
5. Reinstall distributor cap and connect spark plug
wire to spark plug.
i CAUTION I
Do not, under any circumstances, puncture a
spark plug wire when measuring resistance.
Measure only as instructed.
6. Was resistance less than 7,000 ohms per
foot?
BE CERTAIN TO
MAKEGOOO
CONNECTION TO
TERMINAL
A6166-C

ALL RIGHTS RESERVED
PART 2
DURASPARK II
IGNITION SYSTEM.
L.'

ALL RIGHTS RESERVED
Preliminary Checkout, Equipment & Notes
CHECKOUT
are properly routed and securely connected. .
EQUIPMENT
Spark Tester, Special Service Tool 081 P-6666-A. See NOT~.
12 Volt Test Lamp.
Small straight pins (2).
NOTES
All wire colors referred to in this part relate to the colors of the ignition module wires. When
working with a wiring harness, the wires must be trac~d back to the ignition module for
proper color identification.
When instructed to inspect a wiring harness, both a visual inspection and a continuity test
should be performed.
When making measurements on a ~iring harness or connector, it is good practice to wiggle

the wires while measuring.

ALL RIGHTS RESERVED
Part 2
IStart Circuits DS II
Test 1
,TEST STEP RESULT ACTION TO TAKE
1. Conn,ect spark tester between ignition coil wire Yes ~ GO to Part 2, Test 2.
and engine ground.
2. Crank engine using ignition switch. No ~ MEASURE resistance
3. Were sparks present? REPLACE if greater
than 7,000 ohms per
TO IGNITION COtL
foot.
INSPECT ignition'coil
for damage, carbon
tracking.
CRANK engine to
verify distributor
rotation. REFER to
Ignition/Engine Shop
Manual Group (Engine
Group for Compact
Truck) and SERVICE
as required.

ALL RIGHTS RESERVED
IRun Circuits DS II
Part 2
Test 2
TEST STEP RESULT. ~ ACTION TO TAKE
1. Turn ignition switch from OFF to RUN to OFF Yes ~ INSPECT distributor
position several times. capt adapter, rotor for
cracks, carbon tracking.
2. Spark should occur each time switch goes from
RUN to OFF position. CHECK for roll pin
securing armature to
3. Remove spark tester, reconnect coil wire to sleeve in distributor.
distributor cap.
4. Were sparks present? CHECK that ORANGE
and PURPLE wires not
crossed between
distributor and ignition
module.
If ignition module has

Basic Part No.
(-12A244-), GO to
; to check spark retard
operation.
No ~ GO to Part 2, Test 3.
. .
'

ALL RIGHTS RESERVED
Part 2
IModule Voltage DS II
Test 3
TEST STEP RESULT. ACTION TO TAKE
Turn ignition switch off. Yes ~ GO to Part 2, Test 4.

1. Carefully insert small straight pin in RED module
wire. No ~ REFER to vehicle
wiring diagram.
i CAUTION 1 INSPECT wiring
harness between
Do not allow straight pin to contact electrical module and ignition
ground. switch.
2. Attach negative (-) VOM lead to distributor
Damaged or worn
base.
ignition switch. REFER
3. Measure battery voltage. to Charging/Electrical
Shop Manual Group
4. Measure voltage at straight pin with ignition (Electrical Power
switch in RUN position. Supply System Group
14 for Compact Truck).
5. Turn ignition switch to OFF position.
6. Remove straight pin.
7. Is voltage 90 percent of battery voltage or
greater?
IGNITION
SWITCH
IGNITION
MODULE
NOTE:
WIRE SEQUENCE
HAS BEEN ARRANGED
TO SIMPLIFY
SCHEMATIC
A6358-E

ALL RIGHTS RESERVED
Ignltlo~ Systems, Timing Procedures and Diagnosis 1329
IBallast Resistor DS II
Part 2
Test 4
1. Separate and inspect ignition module two wire Yes ~ REPLACE ignition
connector with RED and WHITE wires. module.
2. Disconnect and inspect ignition coil connector.

No ~ REPLACE ballast
3. Measure ballast resistor between BAT terminal of resistor.
ignition coil connector and wiring harness
connector mating with RED module wire.
4. Reconnect all connectors.
5. Was the resistance 0.8 to 1.6 ohms?
IGNJTION
MODULE
NOTE:
WIRE SEQUENCE
HAS BEEN ARRANGED
TOSJMPUFY
SCHEMAnc

ALL RIGHTS RESERVED
ISupply Voltage Circuits DS II

Part 2
Test 5
1. Remove SPARK TESTER, reconnect coil wire to Yes .. Test result OK.
distributor cap.
2. If starter relay has I terminal, disconnect cable GO to Part 2, Test 6.
from starter relay to starter motor.
3. If starter relay does not have I terminal, No ~ REFER to vehicle
disconnect wire to S terminal of starter relay. wiring diagram.
4. Carefully insert small straight pins in RED and INSPECT wiring
WHITE module wires. harness and
connector(s) in faulty
f CAUTION! circuit(s).
Do not allow straight pins to contact electrical Damaged or worn
ground. ignition switch. REFER
5. Measure battery voltage. to Charging/Electrical
6. Following table below, measure voltage at points Shop Manual Group
listed with ignition switch in position shown. (Electrical Power
NOTE: Attach negative (-) YOM lead to Supply System Group
distributor base. Wiggle wires In wiring 14 for Compact Truck).
harness when measuring.
Radio interference
Wire/ Ignition Switch capacitor on ignition
Terminal Circuit Test Position coil.
Red Run Run
White Start Start
'Bat'
Ballast Resistor
Terminal Start
Bypass
Ignition Coil

8. Remove straight pins.
9. Reconnect any cables/wires removed from starter
relay.
10. Is voltage 90 percent of battery voltage or
greater?

ALL RIGHTS RESERVED
Supply Voltage Circuits- Part 2

DS II
Continued Test 5
_ TO IGNITION
SWITCH
TO BATIERY
A6361-C
_ _...
. .., TO DVOM
IGNITION
MODULE
NOTE:
WIRE SEQUENCE
~-~~,..-----...... < -E~ BLA~CK~

__
HAS BEEN ARRANGED
TO SIMPLIFY
SCHEMATIC
AI3eO-D

ALL RIGHTS RESERVED
Part 2
Ignition Coil Supply Voltage DS II
Test 6
1. Attach negative (-) lead of VOM to distributor Yes ~ GO to Part 2, Test 7.

base.
2. Turn ignition switch to RUN position. No ~ GO to Part 2, Test 12.
3. Measure voltage at BAT terminal of ignition coil.

5. Was the voltage 6 to 8 volts?
IGNITION
SWITCH
IGNITION
MODULE
NOTE:
WIRE SEQUENCE
HAS BEEN ARRANGED
TO SIMPLIFY
SCHEMATIC
A8382.o

ALL RIGHTS RESERVED
Distributor Stator Assembly Part 2

DS II
and Wiring Harness Test 7
1. Separate ignition module four wire connector. Yes ~ Test result OK.
Inspect for dirt, corrosion, and damage.
2. Measure stator assembly and wiring harness
resistance between wiring harness terminals
No ~ GO to Part 2, Test 11.
mating with ORANGE and PURPLE module wires.
NOTE: Wiggle wires In wiring harness when
measuring.
3. Was the resistance 400 to 1,300 ohms?
r-----,...-S_.--+-----_
BALLAST REO
IGNITION RESISTOR
SWITCH WHITE
IGNITION
MODULE
NOTE:
WIRE SEQUENCE
HAS BEEN ARRANGED
TO SIMPLIFY
SCHEMATIC
A6363-D

ALL RIGHTS RESERVED
Ignition Module to Distributor Part 2

DS II
Stator Assembly Wiring Harness Test 8
1. Attach one VOM lead to distributor base. Yes ,~ TEST result OK.
2. Alternately measure resistance between wiring GO to Part 2, Test 9.
harness terminals mating with ORANGE and
PURPLE module wires and ground.
No ~ INSPECT wiring
3. Reconnect four wire connector. harness between
module connector and
4. Was the resistance greater than 70,000 ohms? distributor, including
distributor grommet.
,......--~S....---+--=BA':"':'"L':"'"':LA=ST=----,
RED
RESISTOR
IGNITION
SWITCH WHITE
IGNITION
MOOULE
GREEN
PURPLE NOTE:
WIRE SEQUENCE
HAS BEEN ARRANGED
TO SIMPLIFY
BLACK SCHEMATIC
I I
,--------- -------
DISTRIBUTOR
':- BASE
A&364D

ALL RIGHTS RESERVED
-Ignition Systems, Timing Procedures and D~agnosis 1335
Ignition Coil Secondary Part 2

DS II
Resistance Test 9
1. Disconnect and inspect ignition coil connector Yes ~ Test result OK.
and coil wire.
2. Measure secondary resistance from SAT terminal
to high voltage terminal.
No ~ REPLACE ignition coil.
3. Reconnect ignition coil wire.
4. Was the resistance 7,700 to 10,500 ohms?
IGNITION
MOOULE
NOTE:
WIRE SEQUENCE
HAS BEEN ARRANGED
TO SIMPLIFY
SCHEMATIC
aLACK
ORANGE
A63I5-D

ALL RIGHTS RESERVED
Part 2
IModule to Coil Wire DS II
Test to
1. Separate and inspect ignition module four wire Yes .. REPLACE ignition
connector and ignition coil connector from coil. module.
2. Connect one lead of VOM to distributor base.

No .. INSPECT wiring
3. Measure resistance between TACH terminal of harness between
ignition coil connector and ground. ignition module and
coil.
4. Reconnect ignition module and coil connectors.
5. Was the resistance greater than 100 ohms?
_---4' S. . .---+-.....
BA..-L--LA"""'ST---
RESISTOR
RED
IGNITION
SWITCH WHITE
IGNITION
MODULE
GREEN
NOTE:
WIRE SEQUENCE
HAS BEEN ARRANGED
TO SIMPLIFY
SCHEMATIC
DISTRIBUTOR
... BASE
A6366-D

ALL RIGHTS RESERVED
Part 2
Distributor Stator Assembly DS II
Test 11
1. Separate distributor connector from harness. Yes ~ Test result OK.

Inspect fC?r dirt, corrosion, and damage.
INSPECT wiring
2. Measure stator assembly resistance across harness between
ORANGE and PURPLE wires at distributor distributor and ignition
connector. module.
3. Reconnect distributor and module connectors..
No ~ REPLACE stator
4. Was resistance 400 to 1,300 ohms? assembly.
REO
WHITE
IGNITION MODULE
GREEN
PURPLE NOTE:
WIRE SEQUENCE
HAS BEEN ARRANGED
BLACK TO SIMPLIFY SCHEMATIC
ORANGE

ALL RIGHTS RESERVED
Ignition Coil Primary Part 2

DS II
Resistance Test 12
1. Disconnect ignition coil connector. Yes Test result OK.

2. Measure primary resistance from BAT to TACH GO to Part 2, Test 13.
terminal.
3. Reconnect ignition coil connector. No REPLACE ignition coil.
4. Was resistance 0.8 to 1.6 ohms?
IGNITION
IIODUl.E
NOTE:
WIRE seQUENCE
HAS BEEN ARRANGED
TO SlIiIPUFY
SCHEMATIC

ALL RIGHTS RESERVED
Part 2
Primary Circuit Continuity DS II
Test 13
TESTSTEP RESULT ACTION TO TAKE
1. Carefully insert small straight pin in module Yes ~ GO to Part 2, Test 14.
GREEN wire.
f CAUTION! No INSPECT wiring
harness and
Do not allow straight pin to contact electrical connectors between
ground. ignition module and
coil.
base.
3. Turn ignition switch to RUN position.
4. Measure voltage at GREEN module wire.
7. Was Yoltage greater than 1.5 Yolts?
RED
WHITE
IGNITION
MODULE
NOTE:
WIRE seQUENCE
HAS BEEN ARRANGED
TO SIMPLIFY
SCKEIIAnc
DISTRIBUTOR
BASE

ALL RIGHTS RESERVED
Part 2
Ground Circuit Continuity DS II
Test 14
1. Carefully insert small straight pin in module Yes ~ GO to Part 2, Test 15.
BLACK wire.
i CAUTION I No ~ REPLACE ignition
module.
Do not allow straight pin to contact electrical
ground.
base.
4. Measure voltage at BLACK wire.
7. Was voltage greater than 0.5 volts?
RED
WHITE
BAT
IGNITION
MODULE
NOTE:
WIRE SEQUENCE
HAS BEEN ARRANGED
TO SIMPLIFY
SCHEMATIC
DISTRIBUTOR
BASE

ALL RIGHTS RESERVED
Distributor Ground Circuit Part 2

DS II
Continuity Test 15
TEST STEP RESULT ~ ACTION TO TAKE,
1. Separate distributor connector from harness. Yes ~ Test result OK. ..

Inspect for dirt, corrosion, and damage.
INSPECT wiring
2. Attach one lead of VOM to distributor base. harness and
connectors between
3. Measure resistance by attaching other VOM lead
distributor and ignition
to BLACK wire in distributor connector. module.
NOTE: Wiggle distributor grommet when
measuring. No ~ INSPECT ground screw
4. Reconnect distributor connector. in distributor.
5. Was resistance less than 1 ohm?
S
RED
IGNITION
R
SWITCH WHITE
S
IGNITION
MODULE
GREEN
NOTE:
WIRE SEQUENCE
HAS BEEN ARRANGED
TO SIMPLIFY
SCHEMATIC
BLACK
ORANGE
DISTRIBUTOR
BASE
A83720C

ALL RIGHTS RESERVED
PART 2
TFI-IV
IGNITION SYSTEM
.. AND
TFI WITH COMPUTER
CONTROLLED DWELL
. (CCD)

ALL RIGHTS RESERVED
CHECKOUT
Examine all wiring harnesses and connectors for insulation damage, and burned, overheated,
Check that the TFI module is securely fastened to the distributor base.
eQUIPMENT
Obtain the following test equipment or. an equivalent:
Spark Tester, Special Service Tool 081 P-6666-A. See NOTES.
12 Volt Test Lamp.
Small straight pin.
Remote Starter Switch.
TFI Ignition Tester, Rotunda 105-00002.
E-core Ignition Coil E73F-12029-AB.
Ignition coil secondary wire E43E-12A012-AB.
NOTES
When instructed to inspect a wiring harness, both a visual inspection and a continuity test
When making measurements on a wiring harness or connector, it is good practice to wiggle

the wires while measuring. '
References to pin-in-line connector apply to a shorting bar type connector used to set base
timing.
This procedure is intended to identify faultY components or wiring while the fault is present.
If the complaint is of an intermittent condition, refer to Intermittent Diagnosis.

ALL RIGHTS RESERVED
TFI-IV
Functional Schematic And
TFI-IV
With CCD
The TFI-IV system electrical schematic is shown below" For detailed information, refer to the
vehicle wiring diagram.
TO
------~ BATIERY
IGN
SWITCH
I I
(HALL EFFECT)
STATOR
+1
START-------------'
RUN (TFI P W R ) - - - - - - - - - - - - - - '

TFIIV TO
MODULE COIL ( T A C H ) - - - - - - - - - - - - -.... DISTRIBUTOR
CAP
P I P - - - - - - - - - _...
... TO
IGN G N D - - - - - - - - - - I . _ EEe
SPOUT ~"
-------=-- SPOUT INL1NE
CONNECTOR A9367-<:
The TFI-IV with CCO system electrical schematic is shown below. For detailed information,
refer to the vehicle wiring diagram.
_ - - - -........ TO
BATTERY
IGN
SWITCH
(HALL EFFECT)
STA10R
. - . - - RUN (TFI PWR} .....
t - - - - COIL ( T A C H } - - - - - - - - - - - - - ' 10
TFIIV t----PIP DISTRIBUTOR
MODULE t - - - - IGN GND TO CAP
SPOUT ~EEC
- ~~ SPOUT IN-LINE
FILTERED TACH OUTPUT (FTC) CONNECTOR
A9263-A

ALL RIGHTS RESERVED
!gnition Coil . TFI-IV Part 2

Second~1J7 Voltage And
(Crank Mode) TFI With CCD Test 1
TEST STEP , RESULT ~. ACTION TO TAKE
1. Connect spark tester between ignition coil wire Yes ~ Test result OK.
and engine ground.
INSPECT distributor
2. Crank engine. cap and rotor for
.damage/carbon
3. Turn ignition .switch to the OFF position.
tracking.
4. Was spark present?
If engine starts, GO
TO IGNITION COIL to Part 1, Test 2,
otherwise GO to Test
2.

for damage/carbon
tracking.
CRANK engine to
verify distributor
rotation. Refer 'to
Ignition/Engine Shop
Manual Group (Engine
Group 3 for Compact
Truck) and SERVICE
as required.
GO to Test 4.

ALL RIGHTS RESERVED
1346 Ignition Systems, Timing Procedures and Dlagnosl8
~nitionCoil TFI-IV Part 2

Secondary Voltage And
(Run Mode) TFI With CeD Test 2
1. Place the transmission shift lever in the PARK Yes ~ Test result OK.
(A/T) or NEUTRAL (MIT) position and set the
parking brake. Problem is not in the
ignition system.
f CAUTION 1 RETURN to Diagnostic
Routines, Section 2, to
Failure to perform this step may result in the identify possible cause.
vehicle movi~g when the starter is subsequently
engaged during the test.
No GO to Test 3.
2. Disconnect wire at S terminal of starter relay.
3. Attach remote starter switch.
4. Turn ignition switch to the RUN position.
5. Crank the engine using remote starter switch.
6. Turn ignition switch to the OFF position.
7. Remove remote starter switch.
8. Reconnect wire to S terminal of starter relay.
TO IGNITION COIL

ALL RIGHTS RESERVED
TFI-IV Part 2
IWiring Harness And
TFI With CCD Test 3
TEST~STEP RESULT ACTION TO TAKE'
1. Separate wiring harness connector from ignition Yes .. REPLACE TFI module.
module. Inspect for dirt, corrosion, and damage.
NOTE: .Push connector tabs to separate. No .. INSPECT for faults in
2. Verify that the wire to the S terminal of starter wiring harness and
relay is disconnected. connectors.
base. REFER to vehicle
wiring diagram for
4. Measure battery voltage. appropriate circuit.
5. Following the appropriate table below, measure
connector terminal voltage by attaching VOM to Damaged or worn
small ~traight pin inserted into connector terminal ignition switch. REFER
and turning ignition switch to position shown. to Charging/Electrical
Shop Manual (Electrical
i ~~UTION I Power Supply System
Do not allow straight pin to contact electrical Group for Compact
ground. Truck).
TFI without CCO

Connector Ignition Switch
Terminal Wire/Circuit Test Position
#3 Run Circuit Run and Start
#4 Start Circuit Start
TFI with CCO


9. Was the value at least 90 percent of battery
voltage in each case?
~-!-_ _ IGNITIONMODULE
CONNECTOR
TERMINAL
NO.1 A9445-A

ALL RIGHTS RESERVED
IStator - TFI
TFI-IV
And
TFI With CCD
Part 2
Test 4
1. Place ,the transmission shift lever in the" PARK Yes ~ GO to Test 6.

parking brake. No ~ REMOVE distributor
i CAUTION! cap and VERIFY
rotation. If OK, GO to
Failure to perform this step may result in the Test 5.
vehicle moving when the starter is SUbsequently
2. Disconnect the harness connector from the TFI
module and connect the TFI tester.
3. Connect the red lead from the tester to the
positive (+) side of the battery.
4. Disconnect the wire at the S terminal of the
starter relay, and attach remote starter switch.
5. Crank the engine using the remote starter switch
and note the status of the two LED lamps.
6. Remove the tester and remote starter switch.
7. Reconnect the wire to the starter relay and the
connector to the TFI.
8. Did the PIP light blink?

ALL RIGHTS RESERVED
Ignltlon'Systems, Timing Procedures and Diagnosis 13-49
IStator - TFI-IV
TFIWith CCD
TFI-IV
And
Part 2
Test 5
1. Remove the distributor from the engine and the Yes ~ Replace stator.
TFI module from the distributor.
2. Measure resistance between TFI module terminals No ~ Replace TFI.
as shown below.
Measure Between Resistance
These Terminals Should Be
GND-PIP In Greater than 500 Ohms
PIP PWR - PIP IN Less than 2K Ohms
PIP PWR - TFI PWR Less than 200 Ohms
GND-IGN GND Less than 2 Ohms
PIP In-PIP Less than 200 Ohms
3. Are all these readings as specified?
HMMETER
CD
PIP
All"'~I.6.'I '_==.=&Jr---(~ SPOUT
START
TFI PWR
TACH (10M)
. 1 IGN GNO
At440-8

ALL RIGHTS RESERVED
TFI-IV
Part 2
ITFI Module And
TFI-IV
With CCD Test 6
.
.
1. Use status of Tach light from Test 4. Yes GO to Test 7.
2. Did the Tach light blink?
No REPLACE TFI module
and CHECK for spark
using the method
described in Test 1. If
spark was not present
REPLACE the coil also.

ALL RIGHTS RESERVED
Ignition Coil and TFI-IV Part 2

And
Secondary Wire TFI With CCD Test 7
1. Disconnect ignition coil connector. Inspect for dirt, Yes ~ MEASURE resistance
corrosion and damage. of the ignition coil wire
(from vehicle).
2. Connect the ignition coil connector to a known REPLACE if greater
good ignition coil. than 7,000 ohms per
foot.
3. Connect one end of a known good secondary
wire to the spark tester. Connect the other end If OK, REPLACE
to the known good ignition coil. ignition coil.
i CAUTION!
No ~ RECONNECT coil
DO NOT HOLD THE COIL while performing this connector to the
test. Dangerous voltages may be present on the vehicle coil and spark
metal laminations as well as the high voltage tester to vehicle
tower. .secondary wire and GO
to Test 8.
4. Crank engine.
~ KNOWN GOOD COIL AND

SECONDARY WIRE
I-=-o=""'_ _ SPARK
ENGINE _ _~ ~ ~::!!:Ii~=s' TESTER
GROUND
A9262-A

ALL RIGHTS RESERVED
TFI-IV
Part 2
IEEC-IV - TFI-IV
And
TFI-IV Test 8
With CCD
1. Disconnect pin-in-line connector near the Yes ~ CHECK PIP and

distributor. Ignition ground wires
for continuity. SERVICE
2. Crank engine. as necessary. If OK,
GO to EEC-IV
Diagnosis.
TO IGNITION COIL No ~ GO to Test 9.
AIOZ5-C

ALL RIGHTS RESERVED
TFI-IV
And Part 2
.Ignitio~ Coil Supply Voltage TFI-IV
With CCD Test 9
1. Attach negative (-) VOM lead to distributor Yes ~ GO to Test 10.

b~a .
2. Measure battery voltage. No ~ INSPECT and SERVICE
wiring between ignition
3. Turn ignition switch to RUN position. coil and ignition switch.
REFER to vehicle
4. Measure voltage at .pOSITIVE (+) terminal of wiring diagram.
ignition coil.
5. Turn ignition switch to OFF position. Worn or damaged
6. Was the value 90 percent of battery voltage to Charging/Electrical
or more? Shop Manual Group
(Electrical Power
Supply System Group
for Compact Truck).
~
.".I0"
\--LJ
v
A6392B

ALL RIGHTS RESERVED
Part 2
IWiring Harness TFI-IV
Test 10
1. Separate wiring harness connector from ignition Yes ~ INSPECT for faults in
module. Inspect for dirt, corrosion, and damage. wiring between the coil
NOTE: Push connector tabs to separate. and TFI module
terminal No. 2 or any
2. Disconnect the wire at S terminal of starter relay. additional wiring or
3. Attach negative (-) VOM lead to distributor components connected
base. tq that circuit.
4. Measure battery voltage.
5. Following the appropriate table below, measure REFER to vehicle
connector terminal voltage by attaching VOM to wiring diagram.
small straight pin inserted into connector terminal
and turning ignition switqh to position shown. No ~ INSPECT for faults in
i CAUTION! wiring harness and
connectors.
Do not allow straight pin to contact electrical
ground. REFER to vehicle
wiring diagram for
TFI without CCO appropriate circuit.
Terminal Wire/Circuit Test Position Damaged or worn
Run Circuit
#3 Run and Start
to Charging/Electrical
#4 Start Circuit Start Shop Manual Group
(Electrical Power
TFI with CCO Supply System Group
for Compact Truck).

9. Was the value at least 90 percent of battery
voltage In each case?
CD v ~-!-_ _ JGNITJONMODULE
CONNECTOR
A9445-A

ALL RIGHTS RESERVED
. PART 2
TFI-IV
CLOSED BOWL
DISTRIBUTOR

ALL RIGHTS RESERVED
CHECKOUT
Examine all wiring harnesses and connectors for insulation damage. and burned. overheated.
loose. or broken conditions.
EQUIPMENT
Spark Tester. Special Service Tool D81 P-6666-A. See NOTES.
12 Volt Test Lamp.
Small straight pin.
Remote Starter Switch.
TF.I Ignition Tester. Rotund~ 105-00003.
E-Core Ignition Coil E73F-12029-AB.
Ignition Coil Secondary Wire E43E-12A012-AB.
NOTES
When instructed to inspect a wiring harness. both a visual inspection and a continuity test
When making measurements on a wiring harness or connector, it is good practice to wiggle

the wires while measuring.
References to pin-in-line connector apply to shorting bar type connector used to set base
timing.
This procedure is intended to identify faulty components or wiring while the fault is present.
If the complaint is of an intermittent condition refer to Intermittent Diagnosis.

ALL RIGHTS RESERVED
TFI-IV
Functional Schematic Closed Bowl
Distributor
The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed
information, refer to the vehicle wiring diagram.
- ~TO
I ' BATTERY
..... I IGN
P) {9 SWITCH
START
L,J
PWR PWR
..... ~
I"-
IGN
TFI
COIL
~
COIL
-+ TO
OIST CAP
OIST
GNO
PIP-B
SPOUT ,.... PIPA

L.J
IGN GNO
SHIELD
GNO
,
..
~
"'-- ~ SHIELD
,if , If ,if
TOEEC A9442-A

ALL RIGHTS RESERVED
13-58 Ignition Systems, Timing 'Procedures and Diagnosis
Ignition Coil Secondary TFI-IV Part 2

Closed Bowl
Voltage - Crank Mode Distributor Test 1
1. Connect spark tester between ignition coil wire Yes ~ Test result OK.
and .engine ground. INSPECT distributor
cap and rotor for
2. Crank engine. damage/carbon
tracking.
If engine starts, GO to
Part 1, otherwise GO
to Test 2.

for damage/carbon
tracking.
Crank engine to verify

distributor rotation.
REFER to Ignition/
Engine Shop Manual
Group (Engine Group
for Compact Truck)
and SERVICE as
required.
GO to Test 4.
TO IGNITION COIL

ALL RIGHTS RESERVED
Ignition Coil Secondary TFI-IV Part 2

Closed Bowl
Voltage - Run Mode Distributor Test 2
1. Place the transmission shift lever in the PARK

Parking Brake.
Yes . Test result OK.
Problem is not in the
ignition system primary
circuit components.
r~~U'!~~ I RETURN to the
Diagnostic Routines to
Failure' to perform this step may result in the identify other possible
vehicle moving when the starter is subsequently causes.
2. Disconnect wire at S terminal of starter relay. No ~ GO to Test 3.
3. Attach remote starter switch.
5. Crank the engine using remote starter switch.
7. Remove the remote starter switch.
TO IGNITION COIL

ALL RIGHTS RESERVED
TFI-IV Part 2
IWiring Harness Closed Bowl
Distributor Test 3
1. Separate wiring harness connector from ignition Yes ~ REPLACE the TFI
module. Inspect for dirt, corrosion, and damage. module.
NOTE: Push connector tabs to separate.
2. Disconnect wire at S terminal of starter relay. No ~ INSPECT for faults in
3. Attach negative (-) VOM lead to distributor wiring harness and
base. connectors. REFER to
vehicle wiring diagram
4. Measure battery voltage. for appropriate circuit.
5. Following table below, measure connector
terminal voltage by attaching VOM to small Damaged or worn
straight pin inserted into connector terminal and ignition switch. REFER
turning ignition switch to position shown. to Charging/Electrical
f CAUTION! Shop Manual Group
(Electrical Power
Do not allow straight pin to contact electrical Supply System Group
. ground. for Compact Truck).

9. Was the voltage measured greater than 90
percent of battery voltage in each case?
..,~~_ _ IGNITIONMODULE
CONNECTOR
TERMINAL
NO.1 A9445-A

ALL RIGHTS RESERVED
Ignition Systems, Timing Procedures and Diagnosis 13..61
TFI-IV Part 2
IStator . Closed Bowl
Distributor Test 4
1. Separate wiring harness connector from the . Yes ~ GO to Test 5.

distributor. Inspect for dirt, corrosion and damage.
2. Measure resistance between the stator connector No ~ REPLACE the stator.
terminals 1 and 5.
3. Was the resistance between stator terminals 1
and 5 less than 5 ohms?
TERMINAL NO.
2-++-....,..-+tIIPC:X
3-.w-.........-\-tIKX
4--\40~~~
STATOR
CONNECTOR
A11801-A

ALL RIGHTS RESERVED
1362 Ignition Systems,' Timing Procedures and Diagnosis
TFI-IV Part 2
IStator Closed Bowl
Distributor Test 5
1. Measure resistance between stator connector Yes ~ GO to Test 6.

terminal 2 and the distributor base.
2. Measure resistance between stator connector No INSPECT the retaining
terminal 6 and the distributor base. screws to stator in the
distributor bowl. If OK,
3. Was the resistance less than 1 ohm in each REPLACE the stator.
case?
TERMINAL NO.
. 1--#-.~IIRJV~~~~""~
2 -...,....,....POIfa.. DISTRIBUTOR
BASE
STATOR
CONNECTOR A11.1G-A

ALL RIGHTS RESERVED
_C_IO_~_~d_I-_I~_O_W_I---J
p a rt 2
'--s_t_at_o_r --'I. _ ___ 6
I_ Distributor _Test
L--. L-- ---1
TEST STEP RESULT ~ . ACTION TO TAKE
1. Place the transmission shift lever in the PARK Yes ~ RECONNECT harness
(A/T) or NEUTRAL (MIT) position and set the connectors to TFI
parking brake. module and distributor,
then GO to Test 7.
f CAUTION!
Failure to perform this step may result in the No ~ REPLACE the stator.
vehicle moving when the starter is subsequently
2. Disconnect the harness connector from the T.FI
module and connect the TFI-IV tester to the
stator and TFI module.
3. Connect the red lead from the tester to the
positive (+) side of the battery.
4. Disconnect the wire at the S terminal of the
starter relay, and attach remote starter switch.
5. Crank the engine using the remote starter switch
and note the status of the two LED lights. ;
6. Remove the tester and remote starter switch.

7. Reconnect the wire to the starter relay.
8. Did the PIP light blink?

ALL RIGHTS RESERVED
TFI-IV Part 2
ITFI Module Closed Bowl
Distributor Test 7
1. Use status of Tach light from Test 6. Yes ~ GO to Test 8.

2. Did the Tach light blink?
No ~ REPLACE the TFI
module and CHECK for
spark using the method
described in Test 1. If
spark is not present
REPLACE the coil also.

ALL RIGHTS RESERVED
Ignition Coil And TFI-IV Part 2

Closed Bowl
Secondary Wire Distributor Test 8
1. Disconnect ignition coil connector. Inspect for dirt, Yes ~ MEASURE resistance
corrosion and damage. of the ignition coil wire
(from vehicle), if
2. Connect the ignition coil connector to a known greater than 7,000
good ignition coil. ohms per foot. If OK,
REPLACE ignition coil.
3. Connect one end of a known good secondary
wire to the spark tester. Connect the other end
to the known good ignition coil. No ~ RECONNECT coil
connector to the
i CAUTION! vehicle coil and spark
tester to vehicle
DO NOT HOLD THE COIL while performing this secondary wire and GO
test. Dangerous voltages may be present on the to Test 9.
metal laminations as well as the high voltage
tower.
4. Crank engine.
r----_ KNOWN GOOD COIL AND

SECONDARY WIRE
~=""_ SPARK .
ENGINE ~::!!i::IIii~~ TESTER
GROUND--""~
A9262-A

ALL RIGHTS RESERVED
TFI-IV Part 2
IEEC-IV - Wiring Closed Bowl
Distributor Test 9
TEST STEP RESULT ~ ACTION TO TAKE '-
1. Disconnect the in-line connector near the TFI Yes ~ Check PIP-A and IGN
module. GND signal wires for
continuity to EEC.
2. Crank the engine. SERVICE as necessary.
If OK, GO to EEC-IV
Diagnostics.
No ~ GO to Test 10.
TO IGNITION COIL

ALL RIGHTS RESERVED
IWiring Ha~ness TFI-IV

Closed Bowl
Distributor
Part 2
Test 10
1. Separate wiring harness connector from distributor Yes ~ GO to Test 11.

and from the TFI module. .
2. Measure resistance between terminal No. 5 of No ~ INSPECT and SERVICE
the harness connector which connects to the wiring between the
distributor and TFI
distributor and terminal No. 6 of the harness module (PIP-~ circuit).
connector which connects to the TFI module by
inserting a small straight pin.
3. Is the resistance less than 5 ohms?
......--M-- 2
7 --+1--4l+-...( """--f+-- 3
TERMINAL
8--I!!!!!!!~-l """"'+--4
NO.1 HARNESS CONNECTOR
TO TFI MODULE HARNESS
CONNECTOR 1.11114-1.

ALL RIGHTS RESERVED
TFI-IV Part 2
Ignition Coil Supply Voltage Closed Bowl
Distributor Test 11
1. Attach negative (-) YOM lead to distributor Yes ~ INSPECT ignition coil
base. harness connector for
dirt, corrosion, and
2. Measure battery voltage. damage.
INSPECT ignition coil
4. Measure voltage at positive (+) terminal of terminals for dirt,
ignition coil. corrosion, and damage.
5. Turn ignition switch to OFF position. GO to Test 12.
6. Was the voltage at coil positive terminal at
least 90 percent of battery voltage? No ~ INSPECT and SERVICE
wiring between ignition
coil and ignition switch.
REFER to vehicle
wiring diagram.
Worn or damaged
Shop Manual Group
(Electrical Power
Supply System Group
for Compact Truck).

ALL RIGHTS RESERVED
TFI-IV Part 2
ITFI Supply Voltage - Closed Bowl
Distributor Test 12
TEST STEP RESULT ACTION TO, TAKE
1. Disconnect wire at S terminal of starter relay. Yes ~ Test result OK. GO to

2. Attach negative (-) VOM lead to distributor Test 13.
base.
3. Measure battery voltage. No ~ INSPECT for faults in
4. Following table below, measure connector wiring harness and
terminal voltage by attaching VOM to small connectors.
straight pin inserted into connector terminal and REFER to vehicle
turning ignition switch to position shown. wiring diagram for
appropriate circuit.
f CAUTION!
Damaged or worn
Do not allow straight pin to contact electrical ignition switch. REFER
ground. .
Connector Ignition Switch Shop Manual Group
Terminal Wire/Circuit Test Position (Electrical Power
Supply System Group
#3 Run Circuit Run and Start for Compact Truck).

8. Was the voltage measured In each case
greater than 90 percent of battery voltage?
~~ _ _ IGNITION MODULE
CONNECTOR
A9445-A

ALL RIGHTS RESERVED
TFI-IV Part 2
Stator Supply Voltage Closed Bowl
Distributor Test 13
1. Attach negative (-) VOM lead to distributor Yes ~ GO to Test 14.

base.
2. Measure battery voltage. No ~ INSPECT and SERVICE
wiring' between stator
3. Turn ignition switch to RUN position. and ignition switch.
REFER to vehicle
4. Measure voltage at terminal 8 of the harness wiring diagram.
connector which connects to the stator.
5. Turn ignition switch to the OFF position. Worn or damaged
6. Was the result greater than 90 percent of to Charging/Electrical
battery voltage? 'Shop Manual Group
(Electrical Power
Supply System Group
for Compact Truck)..
TERMINAL NO. TERMINAL NO.
5----M;:r
6--~""""'-"{ ).4--M---2
7 ---+I~+-"( w-~--3
DISTRIBUTOR
8 - -....~..c lo+.~--4 BASE
HARNESS
CONNECTOR
A11612A

ALL RIGHTS RESERVED
TFI-IV Part 2
IWiring Harness . Closed Bowl
Distributor Test 14
1. Reconnect the wiring harness connector to the Yes ~ INSPECT for faults in
distributor. wiring between the coil
and TFI module
2. Measure resistance between the distributor base terminal No.2 or any
and terminal No. 1 of the harness connector at additional wiring or
the ignition module. components connected
to that circuit.
3. Is the resistance less than 1 ohm?
REFER to vehicle
wiring diagram.
No . ~ INSPECT and SERVICE

wiring between the
harness connector at
the ignition module and
the harness connector
at the distributor (GND
circuit).
CD
_v + IGNITION MODULE
CONNECTOR
A9448-A

ALL RIGHTS RESERVED
INTERMITTENT
. DIAGNOSIS
PROCEDURE

ALL RIGHTS RESERVED
Preliminary Checkout and Notes
NOTES
This procedure begins with an owner complaint that the engine stops at unexpected times
but can be restarted. In situations like this there are two things that are very important. The
technician must obtain as much information directly from the owner about the conditions
under which the problem occurs, and the service history of the vehicle must be thoroughly
reviewed to avoid repeat replacement of good components. For example, replacing a stator
assembly a second time will not correct a problem if the problem is actually in another area.
Two testers are available for assistance with intermittent. diagnosis. Rotunda Ignition
System Tester D80L-50-BIT is used to diagnose problems in the primary circuit of the
Duraspark ignition systems. It provides a means to direct the technician to a specific area in
the primary circuit. Rotunda Ignition System Tester 007-00008 provides a quick means of
separating primary ignition system problems from fuel, carburetion, EGA or other system
problems causing similar vehicle symptoms. It can' be used on most ignition systems. It will
detect any primary ignition system problem, but it is. particularly useful in detection of
intermittent problems.
CHECKOUT
are properly routed and se~urely _connected. .

ALL RIGHTS RESERVED
Intermittent Diagnosis
STEP 1 \
Talk to owner. ~ Symptoms.
STEP 2.\
Review vehicle service history. ~ Number of previous

repairs and
components replaced.
J
STEP 3 \
Is a Rotunda Ignition System Tester model, Yes ~ FOLLOW test

007-00008 or equivalent available? procedure instructions
supplied with tester.
No ~ GO to Step 4.
STEP 4 I
Will engine start? . Yes ~ GO to Step 5.
No ~ GO to Ignition System
Diagnostic Procedure,
Part 2, Test 1 for
engine ignition system
(Duraspark II, or
TFI-IV).
STEP 5 \
Engine at idle, raise hood, shake wiring harness Yes ~ SERVICE wiring
and pull wires at connectors for ignition harness or connector.
components.
Does engine quit? No ~ GO to Step 6.
STEP 6 \
Engine at idle, close hood, AIC On, blower on Yes ~ GO to Step 10.
medium speed: allow engine to run for 15
minutes. No ~ GO to Step 7.
Does engine quit?

ALL RIGHTS RESERVED
I : Intermittent Diagnosis
STEP 7 1
Engine off, hood closed, hot soak for 10 minutes. Yes ~ GO to Step 8.
Will engine restart?
, No ~ GO to Ignition System
'. Diagnostic Procedure,
Part 2, Test '1 for
(Duraspark II, or
TFI-IV).
STEP 8 I
Engine at idle~ raise hood, shake wiring harness Yes ~ SERVICE wiring
and pull wires at connectors for ignition harness or connector.
components.
Does engine quit? No ~ GO to Step 9.
STEP 91
Road test. Yes ~ GO to Step 10.
Does engine quit?
No ~ Test complete.
(Problem not
duplicated).
STEP 10 I
.' Raise hood, shake wiring harness, pull wires at Yes ~ SERVICE wiring
connectors, separate and reconnect connectors for harness or connector.
ignition components. .
. No ~ GO to Ignition System
Does engine start?
Diagnostic Procedure,
Part 2, Test 1 for
(Duraspark II, or TFI-
IV).

ALL RIGHTS RESERVED
IGNITION SYSTEM
DIAGNOSTIC
PROCEDURE
(DIS)
2.3L EFI TRUCK
(DUAL PLUG)

ALL RIGHTS RESERVED
Ignition Systems, Timing Procedures and' Diagnosis 13-77
Index: 2.3L 'EFI Truck (Dual' Plug) DIS
NOTE: Start all diagnostics with Section 14 (EEC-IV Quick T~st) first. The tests in this
Section are dependent on results from tests conducted in Section 14.
Subject Page
Preliminary Checkout, Equipment and Notes : : 13-78
DIS Diagnostic Cable ; 13-79
2.3L EFI Truck (Dual Plug) DIS Module and Pin-Out 13-80
2.3L EFI Truck (Dual Plug) DIS Wiring Schematic , 13-81
DIS Schematic and Breakout Box Overlay Acronyms ~ 13-82 .
Crankshaft Sensor Description 13-83
2.3L EFI Truck (Dual Plug)' DIS System Descriptio~ 13-84
2.3L EFI Truck (Dual Plug) DIS Block Diagram - 13-85
2.3L EFI Truck (Dual Plug) DIS Waveforms 1~-86
2.3L EFI Truck (Dual Plug) DIS Component Location 13-87
2.3L EFI Truck (Dual 'Plug) DIS. ~inpoint Test qiagnostics 13-88
'f
, ,"

ALL RIGHTS RESERVED
Preliminary Checkout, Equipment and Notes
CHECKOUT
are properly and securely connected.
damaged pins, loose or broken conditions. Check sensor shield connector. Make sure DIS
module mounting screws are tight.
EQUIPMENT (Required)
DIS Diagnostic Cable (Rotunda 007-00044) (refer to Figure 1).
Spark Tester, Neon bulb type (Special Service Tool D89P-6666-A).
Volt/Ohm Meter (Rotunda 014-00407 or equivalent).
Remote starter switch.
EEC-IV breakout box (Rotunda T83L-50-EEC-IV).
Spark Tester, Gap type (Special Service Tool D81 P-6666-A). A spark plug with a broken
side electrode is not sufficient to check for spark and may lead to incorrect results.
Inductive Timing Light (Rotunda 059-00006). Do not use "advance knob" if timing light has
one (it will not work correctly with DIS Ignition Systems).
EQUIPMENT (Recommended)
Dis Module Tester (DMT) Rotunda 007-00071. This tester contains 12 LEOS, 12 Test Jacks
and a built-in interface cable that allows the tester to monitor all DIS module signals.
DIS Coil/Sensor Tester (CSn Rotunda 007-00072. This tester is similar to the DIS Module
Tester (DMT) except it allows monitoring of signals at the sensor and coils.
LED test lamp. A 12 volt test lamp should not be used to test circuit signals. It will load the
circuit and may cause erroneous measurements or improper DIS/EEC-IV operation. (ie.,
engine stall).
NOTES
When making measurements on a wiring harness, both a visual inspection and a continuity
test should be performed. Inspect the connector pins for damage (corrosion, bent or spread
pins, etc.) when directed to remove a connector.
Spark timing adjustments are not possible.
When making voltage checks a GROUND reading means any value within a range of 0 to 1
volt. Also BAT+ readings mean any value that falls within a range of BAT+ to 2 volts less
than BAT+.
When making voltage checks and a reference to ground is made use either the negative
battery lead or cast iron on the engine. BAT + means the positive battery cable at the
battery.
When using the spark plug firing indicator, place the grooved end as close as possible to
the plug boot. Very weak flashing may be caused by a fouled plug.

ALL RIGHTS RESERVED
I' DIS Diagnostic Cable
(INPUT MODULE TEE) (OUTPUT MODULE TEE)
DIS MODULE
(2.3L LEFT COIL PACK TEE)
2.3L LEFT
COIL PACK
BAT - 10 SENSOR SHIELD

BAT + (SHIELD. TEE)
(NOT USED) .
WARNING: DO NOT
CONNECT EEC PROCESSOR
TO THIS CONNECTOR.
BREAKOUT
BOX
A12776C
Figure 1 2.3L EFI Truck (Dual Plug) DIS Hook-Up

ALL RIGHTS RESERVED
2.3L EFI Truck (Dual Plug) DIS Module and Pin-Out
I"'UI"'~/\)-
0
~
o...
0
03:
Ci5
:D
0
t
UP -NOTE: PIN 7 (IGN GND) IS CONNECTED INTERNAllY
~ TO THE TWO LEFT SIDE .
DIS MODULE MOUNTING HCLES.
:!l WHEN THE DIS MODULE IS BOLTED
TO THE INTAKE MANIFOLD PIN 7
o. 1 0 IS GROUNDED. THIS IS THE
-/ SOURCE OF IGND.
I
:....,C<D5:::;;S
0

A12777B
Figure 2 2.3L EFI Truck (Dual Plug) DIS Module and Pin-Out
2.3L EFI Truck

PIN :#
(Dual Plug)
1 VBAT
2 CID
3 PIPD Out
4 PIP In
5 SPOUT
6 DPI
7 IGN GROUND
8 COIL 3
9 COIL 4
10 COIL 2
11 COIL 1
12 10M

ALL RIGHTS RESERVED
~
CRANKSHAFT ::J
SENSOR -
=:;
0"
~ ~

::J
~ ~ tn
r- -
'<
Q)
(I)
t.)
PIP 56 CD
m 3
!\)
~
.~
(VBAT Sl
r--------
SPOUT 36
IGN GND 16
DPI32
TO
EECIV
PROCESSOR
...
~
Y'
-t
3"
......
:;i
c::
I'
I CASEGND
IDM4
...c~ s-
ea
'V
~ I n an
'0
-
~ _I_I_I.)!
_'_1_ 1-
I
m~+ 1T- ~
~
0
CD
a.
c.,
CD
(I)
~ (RC1D)
C
~
-..;;..
S2
(RC2D)
(LC4D) ....
s:
S
::J-
a.
C/)
;E
~.
(LC3D)
6 16
v
U u
(") 6 16
C\I
U
...
U
....C
~
C
iii"
cc
::J
o
5 do do f;. !f. tQ (I)
ea SPOUT IN-LINE in
"""'"
C/)
g.
(I)
~
PINS 1-6 ' CONNECTOR
____________
DISMODULE~
PINS T-12
...0
(I}
~
~
....
O~."""-------------------------------~~:!...--"'---_.s!..~~--.:J
BAT +-<5
.......
EEC POWER
RELAY SPARK PLUG PACK
LEFT COIL I
RIGHT COIL PACK
:s
LCOIL3:3
LVBAT
c 4'
...
C~3
~4
RCOIL1:=3
RVBAT .
C~:
c+ ~3
tQ
(I}
n
LCOIL4 _ ~2 RCOIL2 _ ~ 2 :r
ft)
LEFT SIDE COIL
NOTE: CONNECTORS ARE SHOWN LOOKING INTO THE WIRING HARNESS.

RIGHT SIDE COIL
as:
IGN GND IS A LOW CURRENT REFERENCE FOR THE EECIV PROCESSOR AND DIS MODULE.
IT IS CONNECTED TO BATTERY NEGATIVE (GROUND) VIA THE DIS MODULE METAL BASE ........
PLATE. PROPER SYSTEM OPERATION DEPENDS ON A lOW RESISTANCE PATH TO GROUND. A12778-C
n
ALL RIGHTS RESERVED
....w
m
....
DIS Schematic and Breakout Box Overlay Acronyms
There is a logic to the names on the Schematic and Overlays for the DIS DIAGNOSTIC
HARNESS that will help you.
DIS Acronyms
PIP Profile Ignition Pickup (Crankshaft Sensor signal).
CIO Cylinder IDentification.
SPOUT SPark OUT (EEC Spark control signal).
10M Ignition Diagnostic Monitor (Diagnostic signal to EEC-IV).
BAT + Battery Positive.
BAT - Battery Negative.
IGGNO Low current ground reference.
OPI Dual Plug Inhibit (High - Right Plugs fire; Low - Both Sides fire).
RC1, RC2 Right Coil Drive (For Coils 1 and 2 right side of engine).
LC1, LC2 -Left Coil Drive (For Coils 1 and 2 left side of engine).
Overlay Designators .
On the Schematic and Overlays, each of these signals is identified along with a suffix letter
that tells you where the measurement is being taken. The key to thes~ letters is:
Prefix "J" is a breakout box jack.
Suffix "D" is at the DIS Module.
Suffix "S" or "PS" or "CS"

is at the sensor, "P" for PIP, "C" for CID.
Suffix "EEC" is at the signal source (the sensor) except PIPEEC which
comes from the DIS Module.
Suffix "C" is at the coil.
A couple of examples:
RCID means Right Coil, number "1", at the DIS Module
Terminal.
RCIC means Right Coil, number "1" I at the Coil Terminal.
VBAT PS means VBAT at the PIP Sensor.
VBAT 0 means VBAT at the DIS Module.

ALL RIGHTS RESERVED
Crankshaft Sensor 'Description
The Dual Hall crankshaft sensor contains two Hall digital output devices (PIP, CID) in one
package. The sensor is located on a' bracket mounted near the crankshaft damper.
Two rotary vane cups (or wheels) are mounted on the damper and are used to trigger the
Hall sensors. The vane cups are made of ferrous metal. When the window of a cup is in the
air gap between the Hall device and the' permanent magnet, a magnetic flux fiela is completed
from the magnet through the Hall device and back to the magnet. This condition results in a
low (0 volt) output signal (Figure 4). As the crankshaft turns, a tooth' on the cup will move.
into the air gap. The magnet field will be shunted by the tooth (Figure 5) preventing it from
reaching the hall device and the output signal will change from a low to a high (VBAT).
The PIP cup has two teeth resulting in two positive going edges each revolution of the
crankshaft, and the CID cup has one tooth and generates one positive edge revolution of the
crankshaft. CID is used by the DIS module to enable it to select the proper coil to fire. The
EEC IV processor tells the DIS module when to fire but the DIS module has to select one of
the two coils based on CID signal (which two of four coils if in the OPI mode).
PERMANENT
MAGNET . HAll
EFFECT
HAll EFFECT DEVICE
DEVICE
VANE
OUTPUT = 0 VOLTS A927G-A OUTPUT = V BATTERY A12779-A
Figure 4 Magnetic Flux Field Figure 5 Hall Effect Device Response to

Vane

ALL RIGHTS RESERVED
2.3L EFI Truck (Dual Plug) DIS System Description
The 2.3L EFI Truck (Dual Plug) Distributorless Ignition System (DIS) (refer to Figure 6) consists
of a crankshaft mounted Dual Hall Sensor, two 4-tower DIS coil packs, and a DIS ignition
module.
The DIS eliminates the need for a distributor by using multiple ignition coils. Each coil fires
two spark plugs at the same time. The plugs are paired so that as one fires during the
compression cycle the other fires during the exhaust stroke. The next time. the coil is fired, the
plug that was on exhaust will be on compression and the one that was on compression will
be on exhaust (the spark in the exhaust cylinder is wasted but little of the coil energy is lost).
Two coils are mounted together in a coil pack". Each coil pack has two tach wires, one for
II
each coil. Since there are two plugs per cylinder, two coil packs are required. One is called
the Right Coil Pack (on right side of engine) and the other, the Left Coil Pack (left side). The
Right Coil Pack and plugs operate continuously but the Left Coil Pack and plugs may be
switched on or off by the EEC-IV processor. The EEC-IV processor computes the spark angle
and dwell for the ignition system.
The Crankshaft Sensor is a dual digital output Hall device that responds to two rotating
metallic shutters mounted together on the crankshaft. The PIP output is a 50 percent duty
cycle signal that provides base spark timing information. The other signal (CID) is required so
that the DIS module "knows" which coil to fire. CID is high (VBAT) half of the crank
revolution (180 degrees) and low (0 volts) for the other (refer to Figure 7).
The EEC-IV processor determines spark angle using the PIP signal to establish base timing.
Spout is sent from the EEC-IV processor to the DIS module and serves two purposes; the
leading edge fires the coil and the trailing edge controls the dwell time. This feature is called
. CCD or computer controlled dwell.
The Ignition Diagnostic Monitor (IDM) is an output from the DIS module to the EEC-IV
processor Module that provides diagnostic information about the ignition system for Self-Test.
Dual Plug Inhibit (DPI) allows the EEC-IV processor to switch the ignition system from single
to dual plug operation.
During crank the vehicle is in the single plug mode (only the plugs on the right side of the
engine are firing). The EEC-IV processor sends a command to the DIS module to switch to
the Dual plug mode (both plugs in each cylinder are firing) when the engine has started.
If the CID circuit fails, the DIS module will randomly select one of the two coils to fire. If hard
starting results, turning the key off and then cranking again will result in another guess."
II
Several attempts may be needed until the proper coil is selected, allowing the vehicle to be
started and driven 'until repairs can be made. The Failure Mode Effects Management (FMEM)
system will keep the vehicle drivable in the event of EEC-IV system or ignition failures that
would otherwise prevent spark angle or dwell commands. The EEC-IV processor opens the
SPOUT line and the DIS module fires the coils directly from the PIP output. This results in a
fixed spark angle of 10 degrees and fixed dwell.
The 2.3L EFI (Dual Plug) DIS component locations are shown in Figure 8.

ALL RIGHTS RESERVED
2.3L EFI Truck (Dual Plug) DIS Block Diagram
SENSORS
10 0 ATDC
RIGHT
DIS COIL PACK
1 BAT
DIS 4
2 CID MODULE 3
ASSY 2
1
4
3
2
i + 12V
BAT
ENGINE
IGNSW
EEC-IV PWR RELAY
TO TACH ....---4~. ..~---VBAT- - - - - - 4 .......- -. .
56 4 36 32 16
ll.
a:::
a:::
o az
0
EEC-IV
PROCESSOR
A12781C
Figure 6 2.3L EFI Truck (Dual Plug) Distributorless Ignition System (DIS)

ALL RIGHTS RESERVED
2.3L EFI Truck (Dual Plug) DIS Waveforms
riming Diagram
roc TOC
~
PIP L
360CRANKDEGREES"':
----
I .
:j~:r..:.aTDC J.9o~'" I:
. I II~~I_-
CID ~1800 -----1.... 1800 ~
~. '..__ 055 ALLOWED
SPOUT
It+ 900~.
I 900 I
I FiRE FiRE
g:~RENT : : n/CYL1AND4 rVCYL1AND4
(PINS 8 AND 11) I I .
I I I I
COIL I I FIRE CYL I FIRE CYL
CURRENT ; rI~_2_A_N.D_3_ _I_ _ rJ~__2_A_ND_3 _
(PINS9AND10)"'y L / C-
. I I I I
10M SHOWN I I I
2-SPARK MODE.' I '...-_
DPI- 0
I THIS VIEW SHOWS THE VANE CUP

AS INSTALLED ON THE ENGINE.
A12782B
Figure 7 2.3L EFI Truck (Dual Plug) DIS Waveforms

ALL RIGHTS RESERVED
2.3L 'EFI Truck (Dual Plug) DIS

.Component Location
RIGHT COIL PACK
GROUND SHELD
CONNECTOR
~~~~~,,;;;~. ~/"I~,'~.,+-LEFT COIL PACK

~
1J.di:!C.~/
FRONT OF ENGINE
DUAL HALL
/
CRANKSHAFT SENSOR
DUAL HALL CRANKSHAFT

SENSOR DETAIL
A12783-8
Figure 8 2.3L EFJ Truck (Dual Plug) DIS Component Location

ALL RIGHTS RESERVED
2.3L EFI Truck (Dual Plug) DIS Pinpoint

Index
Pinpoint Test Diagnostics Test
A 12 volt Test Lamp should not be used to test circuit signals. It will load the circuit
and may cause erroneous measurements or improper DIS/EEC-IV operati~ns (ie. Engine
stall).
INote I
Use a VOM or the LED test lamp circuit (Figure 1) in the following Pinpoint Test
Procedures. The LED Test Lamp is more convenient and faster to use.
If a VOM is used, correct Test Lead Polarity must be followed. The red lead is (+) positive
and' the black lead is (-) negative.
-
To check PIP or CID, the engine is "Bumped" with the starter while watching the voltmeter.
Both the CID and PIP signals are digital and should switch between VBAT and ground as
the engine turns. To see the signal change. using the VOM, the engine must be turned in
very short bursts.
If an LED Test Lamp is used, wire the LED as shown below:
:
LED 1
R1 1-----'
~
LED 1 RADIO SHACK 276-012 DUAL LED
. . R1 RADIO SHACK 271-019 470 f\
R2 RADIO SHACK 271-019 CO/\
THE LED TEST LAMP IS "ON" IF EITHER THE RED OR GREEN

LED IS LIT. A12748A
Figure 1

ALL RIGHTS RESERVED
2.3L EFI Truck (Dual Plug) DIS' Pinpoint

Index
These diagnostics were written to catch Hard faults";

II
- .,
intermittent failures will be difficult or impossible to

diagnose using these procedures.
.....
Engine No Start .... GO to IA11.
.,
Engine runs with:
- Continuous Memory Code 19 ~ GO to 181/.
- Continuous Memory Code 28 ~ GO to 00]..
- Continuous Memory Code 48 ......... GO to IC11.
- Continuous Memory Code 18 ~ GO to [QIJ.
- Continuous Memory Code 88 ~ GO to[ll].
- lack of power drive complaint ~ GO to [IT).
- engine running Code 18 ~ GO to [IT).
- misfire under load ~ GO to IG11.
- intermittent miss or stall ~ GO to [H1J. I
o'
.

ALL RIGHTS RESERVED

A
No Start Test
A1 I PERFORM EEC-IV QUICK TEST
Refer to Section 14 and perform EEC-IV Quick Yes ~ SERVICE any EEC-IV
Test. code first. If still no
start, GO to IA21 .
Are 'any service codes (KOEO, KOER or
Continuous Memory) present?
No ~ GO to IA21.
A2 I CHECK FOR SPARK DURING CRANK
Using a Neon Bulb Spark Tester (D89P6666-A), Yes ~ GO to IA31.

check for spark at each right side spark plug wire
while cranking. No ~ GO to IAsl.
Was spark present on all right side spark plug
wires and consistent (one spark per crank
revolution)?
A3 I CHECK DIS MODULE PIP OUT
Install diagnostic cable. Yes ~ GO to IA41.

Connect diagnostic cable to breakout box.
No ~ REPLACE the DIS
Use 2.3L overlay. module and RERUN
Quick Test.
Connect LED test lamp between (+) J31 (PIP
EEC) and (-) J60 (BAT -).
Crank engine.
Does LED test lamp blink, continuously during
crank?
A4 I CHECK PIP OUT CONTINUITY
Key off. Yes ~ GO to Section 17,

Pinpoint Test Step A.
Disconnect EEC-IV processor.
Measure the resistance between Pin 56 of the No ~ SERVICE open circuit.
EEC-IV vehicle harness connector and J31 (PIP RECONNECT the EEC-
EEC). IV processor and
RERUN Quick Test.

ALL RIGHTS RESERVED
Ignition' Systems, Timing Procedures and Diagnosis 13-91

A
No Start Test
. A5 I DETERMINE MISSING SPARK COMBINATION
Was spark missing f~om BOTH cylinders 1 and Yes ~ GO to IA71.

4 plug wires?
or No ~ GO to IA61.
Was spark missing from both cylinders 3 and
2 plug wires?
A6 I CHECK PLUGS AND WIRES
Check spark plug wires for insulation damage, Yes ~ REINSTALL the PI~
looseness, shorting or other damage. and wires. GO to A7 .
Remove and check spark plugs for damage, wear,
carbon deposits and proper plug gap. No ~ SERVICE or REPLACE
Are .the spark plugs and wires OK? the damaged part, then
RERUN Quick Test. .
A7 I CHECK DIS MODULE VBAT
Install diagnostic cable. Yes ~ GO to IAsl.

Use 2.3L overlay. No ~ CHECK connectors,
SERVICE or REPLACE
Connect LED Test Lamp between (-) J2 (IGN D) the harness. RERUN
and (+)J5 (V~AT D). Quick Test.
Key on.
Is LED test lamp on?
..
AS I CHECK DIS MODULE IGNITION GROUND
Key off. Yes ~ GO to IA101.

Is the resistance between J2 (IGND-D) and J60
(BAT -) less than 5 ohms? No ~ GO to IA91.
A9 I CHECK DIS MODULE MOUNTING SCREWS
Check' DIS module mounting screws for corrosion Yes ~ REPLACE DIS module
or looseness. and RERUN Quick
Test.
Are the mounting screws clean and tight?
.No ~ TIGHTEN, CLEAN or

REPLACE mounting
screws.
CLEAN mounting area
on DIS module.
RERUN Quick Test

ALL RIGHTS RESERVED

A
No Start Test
A10 f CHECK RIGHT COIL PACK CIRCUITS .

Key on. Yes ~ GO to IA141.
Connect LED test lamp between the two pairs of
Test Jacks given below. Note if the LED test No ~ GO to IAlll.
lamp is on or off each time.
Check between (+) J18 (RC1 D) and (-) J60
(BAT -).
Check between (+) J10 (RC2D) and (-) J60
(BAT -).
Was LED test lamp on both times?
A11 I RIGHT COIL FAULT-ISOLATE DIS MODULE
Key off. Yes ~ REPLACE the DIS

Disconnect diagnostic cable connector from DIS module and RERUN
.. module (Pins 7-12). Quick Test.
Repeat test 'procedure in A10.
Was the LED test lamp on both times?
No ~ GO to IA121.
A12 I CHECK RIGHT COIL PACK VBAT
Connect LED test lamp between (+) J26 (VBAT Yes ~ GO to IA131.
R) and (-) J60 (BAT - ).
Is LED test lamp on? No ~ CHECK connectors,
SERVICE or REPLACE
the harness. RERUN
Quick Test.
A13 I CHECK RIGHT COIL CIRCUIT
Connect LED test lamp between (+) J23 (RC1 C) Yes ~ One or both coil wires
and (-) J60 (BAT -). are shorted to VBAT.
Connect LED test lamp between (+) J24 (RC2C) Service connectors and
and (-) J60 (BAT - ). harness. RERUN Quick
Test.
Was LED test lamp on both times?
"
No ~ REPLACE right coil
pack and RERUN
Quick Test.
A14 I CHECK PIP D AT DIS MODULE
Connect LED test lamp between (+) J32 (PIP D) Yes ~ GO to IA1SI.
and (-) J60 (SAT - ).
Crank engine. No ~ GO to IA191.
Does LED test lamp blink continuously during
crank?

ALL RIGHTS RESERVED
2.3L EFI Truck (Dual Plug) DIS Pinpoint"

A
No Start Test
A 15 I CHECK DIS MODULE COIL DRIVERS ..
.
.
Connect LED test lamp between each of the two Yes .GO to IA161 ..
pairs of test points given below. Crank the engine
each time. See if LED test lamp blinks No REPLACE the DIS
continuously during crank.
module and RERUN
Check between (+) J 18 (RC1 D) and (-) J60 Quick Test.
(BAT -).
Check between (+) J10 (RC2D) and (-) J60
(BAT -).
Does LED test lamp I;link each time?
~
A16 I CHECK RIGHT COIL PACK VBAT
.
.
Connect LED test lamp between (+) J26 (BAT R) Yes GO to IA171.
and (-) J60 (BAT - ).
Is LED test lamp on? No CHECK connectors,
SERVICE or REPLACE
the harness. RERUN
Quick Test.
A17 I CHECK RIGHT COIL CIRCUIT

I
~ GO to IA181.
.
Connect LED test lamp between each of the two Yes
test point pairs listed below.
Check to see if LED test lamp is on or off at No One or both coil wires
each step. shorted to ground. Coil
pack may be damaged.
Check between (+) J23 (RC1 C) and (-) J60
CHECK connectors,
(BAT -).
SERVICE or REPLACE
Check between (+) J24 (RC2C) and (-) J60 the harness. RERUN
(BAT -). Quick Test.
Was LED test lamp on in both steps?
I CHECK
A18 RIGHT COIL CIRCUIT
.. Repeat test procedure in Step IA171 and Crank

engine each time.
Yes , . REPLACE the right coil
pack and RERUN
.
I
Quick Test.
Did LED test lamp blink continuously during
crank?
No. One or both coil wires
are open. CHECK
connectors, SERVICE
or REPLACE the
harness. RERUN Quick
Test.

ALL RIGHTS RESERVED

A
No Start Test
A19 I ISOLATE DIS MODULE FROM PIP 0

Disconnect diagnostic cable connector from DIS
module (Pins 1-6). No ~ GO to IA201.
Connect LED test lamp between (+) J32 (PIP D)
and (-) J55 (IGND S).
crank?
A20 I CHECK CRANKSHAFT SENSOR VBAT
Key on. Yes ~ GO to IA211.

Connect LED test lamp between (+) J56 (VBAT
S) and (-) J2 (IGND D). No ~ CHECK connectors,
SERVICE or REPLACE
Is LED test lamp on? the harness. RERUN
Quick Test.
A21 ICHECK CRANKSHAFT SENSOR IGNITION

GROUND
Key off. Yes ~ . GO to IA221.

No ~ CHECK connectors,
Disconnect diagnostic cable connector from SERVICE or REPLACE
crankshaft sensor. the harness. RERUN
Quick Test.
Is the resistance between J55 (IGND S) and
J60 (BAT -) less than 5 ohms?
A22 I CHECK CRANKSHAFT SENSOR PIP S
Connect EEC-IV processor. Yes ~ PIP is open between

sensor and DIS
Connect diagnostic cable connector to crankshaft module. CHECK
Connect LED test lamp between (+) J33 (PIP S) connectors, SERVICE
and (-) J2 (IGND D). or REPLACE the
Does LED test lamp blink continuously while Test.
the engine Is cranked?
No ~ GO to IA231.

ALL RIGHTS RESERVED
Ignition Systems, Timing Procedures and Diagnosis 13..95

A
No Start Test
A23 I CHECK PIP CIRCUIT FOR SHORT TO GROUND
Key off. Yes ~ PIP is shorted to

ground between the
Disconnect diagnostic cable connector from sensor and the DIS
crankshaft. module. CHECK
Disconnect diagnostic cable connector from DIS connectors, SERVICE
module (Pins 1-6). or REPLACE the
harness. RE~UN Quick
Connect LED test lamp between (-) J33 (PIP S) Test.
and (+) J57 (BAT+).
Key'on. No ~ GO to IA24/.
A24 I CHECK PIP CIRCUIT FOR SHORT TO VBAT
Connect LED Test Lamp between (+) J33- (PIP S) Yes ~ - PIP is shorted to VBAT
and (-) J60 (BAT - ). between the sensor
and DIS module.
Is LED test lamp on? CHECK connectors,
SERVICE or REPLACE
the harness. RERUN
Quick Test.
No ~ GO to IA2S/.
A25 I CHECK CRANKSHAFT VANE
Does the crankshaft vane move through the Yes ~ REPLACE crankshaft
sensor air gap when the engine is cranked? sensor and RERUN
Quick- Test.
.
No ~ Refer to Shop Manual,
Compact Truck Group
03.
A2611S0LATE EEC-IV PROCESSOR FROM PIP

CIRCUIT
Key off. Yes ~ REPLACE the

processor. RERUN
Reconnect diagnostic cable connector to DIS . Quick Test.
module (Pins 1-6).
Disconnect EEC -IV processor. No ~ GO to IA271.
Does LED test lamp blink continuously when
the engine is cranked?

ALL RIGHTS RESERVED

A
No Start Test
TEST STEP
A271 CHECK PIP EEC CIRCUIT FOR SHORT TO

VBAT
RESULT
ACTION TO TAKE
Key off. Yes ~ PIP EEC is shorted to

BAT. CHECK
Disconnect diagnostic cable connector from DIS connectors. SERVICE
Connect LED test lamp between (+) J31 (PIP
Test.
EEC) and (-) J60 (BAT -).
Key on. No ~ GO to IA281.
A281 CHECK PIP EEC CIRCUIT FOR SHORT TO

GROUND
Connect LED test lamp between (-) J31 (PIP Yes ~ PIP EEC is shorted to
EEC) and (+) J57 (BAT+). ground. CHECK
connectors, SERVICE
Is LED test lamp on? or REPLACE the
Test.
No ~ REPLACE DIS module

and RERUN Quick
Test.

ALL RIGHTS RESERVED

Continuous Memory Code 28: CID 8
Failure, 10M Low or Right Coil Pack Failure Test'
B1 I VERIFY "HARD CRANK"
Does the vehicle require more than one or Yes ~ GO to IB21.

two attempts to start and when it will not
start, is the cranking speed erratic? No ~ GO to IBsl.
B2 I CHECK CID SIGNAL AT DIS MODULE
Key off. Yes ~ REPLACE DIS module

and RERUN Quick
Install diagnostic cable. Test.
Use 2.3L DP overlay.
No ~ GO to 1831 ..
Connect LED test lamp between (+) J51 (CID D)
and (-) J2 (IGND D). . -
Start engine.
Does LED test lamp blink continuously?-
B3 I ISOLATE DIS MODULE FROM CID CIRCUIT

and RERUN Quick
Disconnect diagnostic cable connector from DIS Test.
module (Pins 1-6).
Crank the engine. No ~ GO to 1841.
crank?
B4 ICHECK CRANKSHAFT SENSOR CID SIGNAL

OUTPUT. .
Key off. Yes ~ CID circuit is open.

CHECK connectors, .
Reconnect diagnostic cable connector to DIS SERVICE or REPLACE
module (Pins 1-6). the harness. RERUN
Quick Test.
Connect LED test lamp between (+) J35 (CIDS)
and (-) J60 (BAT - ).
No ~ GO to IB51.
Start the engine.
Does LED test lamp blink continuously?

ALL RIGHTS RESERVED

Continuous Memory Code 28: CID B
Failure, 10M Low or Right Coil Pack Failure Test
85 ICHECK CID FOR CIRCUIT SHORT TO

GROUND .
Key off. Yes ~ CID is shorted to

ground. CHECK
Disconnect diagnostic cable connector from
connectors, SERVICE
crankshaft sensor.
or REPLACE the
Disconnect diagnostic cable connector from DIS harness. RERUN Quick
module (Pins 1-6). Test.
Connect LED test lamp between (-) J51 (CID D)
and .<+) J57 (BAT +). No ~ GO to 1861.
Key on,
86 I CHECK CID FOR SHORT TO VBAT
Connect the LED test lamp between (+) J51 (CID Yes ~ CID is shorted to
D) and (-) J60 (BAT - ). VBAT. CHECK
Is the LED test lamp on? connectors, SERVICE
or REPLACE the
Test.
No ~ GO to 1871.
87 I CHECK CID VANE
Does the CID vane move through the. sensor Yes ~ REPLACE crank sensor
air gap when the engine is cranked or and RERUN Quick
running? Test.
No ~ REFER to Shop
Manual Compact Truck
Group 03.
88 I CHECK DPI SIGNAL AT DIS MODULE
Key off. Yes ~ GO to 18111.

Install diagnostic cable.
No ~ GO to 1891.
Use 2.3L overlay.
K~y on.
Connect LED Test Lamp between (+) J54 (DPI)
and (-) J60 (BAT - ).
is LED test lamp on?

ALL RIGHTS RESERVED

Failure, 10M Low or Right Coil Pack Failure Test
89 I ISOLATE DIS MODULE FROM DPI CIRCUIT

module' (Pins 1-6). No ~ REPLACE DIS module
and RERUN Quick
Key on. Test.
810 IISOLATE EEC-IV PROCESSOR FROM OPt

CIRCUIT
Key off. Yes ~ DPI is shorted to

VBAT. CHECK
Disconnect EEC-IV processor. connectors, SERVICE
Connect LED test lamp from (+) J54 (DPI) and or REPLACE the
( -) J60 (BAT - ). harness. RERUN Quick
Test.
Keyon.
Is LED test lamp on? No ~ REPLACE the
processor. RERUN
Quick Test.
811 I CHECK IDM SIGNAL AT DIS MODULE
Connect LED test lamp between (+) J4 (10M) and Yes ~ IDM OK at DIS
( -) J60 (BAT - ). module. REPLACE
processor. RERUN
Start engine. . Quick Test.
No ~ GO to 18121.
812 I ISOLATE EEC-IV PROCESSOR FROM 10M

. CIRCUIT
Key off. Yes ~ . The processor is

holding J4 (IDM) low.
Disconnect EEC-IV processor. REPU\CE the
Does LED test lamp blink continuously when processor. RERUN
the engine Is cranked? Quick Test.
No
GO to 18131.

ALL RIGHTS RESERVED

Failure, IDM Low or Right Coil Pack Failure Test
TEST STEP
B131 CHECK IDM CIRCUIT FOR SHORT TO

GROUND '
RESULT
ACTION TO TAKE
Key off.
Disconnect HEGO sensor.
Yes
IDM is shorted to
ground between the
DIS module and
processor. CHECK
connectors, SERVICE
module (Pins 7-12).
or REPLACE harness.
Is resistance between J4 (10M) and J60 RERUN Quick Test.
(BAT -) less than 10K ohms?
No
REPLACE the DIS
module and RERUN
Quick Test.

ALL RIGHTS RESERVED
. Ignition Systems, Timing Procedures and Diagnosis 13-101
2.3L EFI Truck (Dual Plug) DIS . Pinpoint

Continuous Memory Code 48: .
Test
c
Left Coil Pack Failure or 10M Open or High
C1 I CHECK FOR SPARK - LEFT SIDE
Using a Neon .Bulb Spark Tester (D89P-6666-A), Yes ~ GO to IC21.

check for spark at each left spark plug wire with
the engine running. 1011.
No ~ GO to
Was spark present at one or more plugs?
C2 I CHECK DIS MODULE 10M OUTPUT SIGNAL
Key off. Yes ~ GO to IC31.

No ~ GO to IC41.
Use 2.3L overlay.
Connect LED test lamp between (+) J4 (10M) and
( -) J60 (BAT - ).
Start engine.
C3 ICHECK 10M CIRCUIT CONTINUITY TO EEC-IV

PROCESSOR
Key off. Yes ~ 10M OK in DIS

System. REPLACE
Disconnect EEC-IV processor. processor. RERUN
Is the resistance between Pin 4 (10M) of the Quick Test.
EEC-IV vehicle harness connector and J4 (10M)
less than 5 ohms? No ~ 10M circuit is open.
CHECK connectors,
SERVICE or REPLACE
the harness. RERUN
Quick Test.
C4 I
ISOLATE EEC-IV PROCESSOR FROM 10M
CIRCUIT
Key off. Yes ~ The processor is

shorting 10M.
Disconnect EEC-IV processor. REPLACE the
Does LED test lamp blink continuously during processor. "RERUN
crank? Quick Test.
No ~ GO to Icsl.

ALL RIGHTS RESERVED

Continuous Memory Code 48:
Test
c
Left Coil Pack Failure or 10M Open or High
C5 I CHECK 10M CIRCUIT FOR SHORT TO VBAT
Key off. Yes ~ IDM is shorted to

VBAT.CHECK
Disconnect HEGO sensor. connectors, SERVICE
Disconnect diagnostic cable connector from DIS or REPLACE the
module (Pins 7-12).
Test.
Disconnect LED test lamp.
Is the resistance between J4 (10M) and J5 No ~ GO to IC61.
(VBAT 0) less than 10K ohms?
C& I CHECK 10M CIRCUIT FOR SHORT TO

GROUND
Key off. Yes ~ 10M is shorted to

ground. CHECK
Disconnect diagnostic cable connector from DIS connectors. SERVICE
Is the resistance between J4 (10M) and J&O
Test.
(BAT -) less than 10K?

and RERUN Quick
Test.

ALL RIGHTS RESERVED

Continuous Memory Code 18: D
Coil Failure' . Test
D1 I CHECK SPARK - ALL WIRES
Using the Neon Spark Tester (D89P-6666-A), Yes ~ GO to [TI].

check for spark at each plug wire with the engine
running. No ~ GO to 1021.
Was spark present at ALL spark plug wires?
D2 I CHECK SPARK - RIGHT SIDE
Was spark present on ALL right side spark Yes ~ GO to 1031.

plug wires?
No ~ GO to 10101 ..
D3 I LEFT SPARK FAULT -ISOLATE PLUGS/WIRES
Was spark missing from BOTH cylinders 1 and Yes ~ GO to 1051.

4 or BOTH cylinders 2 and 3?
No ~ GO to 1041.
04 ILEFT SPARK FAULT - CHECK PLUGS AND

WIRES
Check left spark plug wires for insulation damage, Yes ~ REINSTALL the plugs
looseness, shorting or other damage. and RECONNECT the
;
plug wires.
Remove and check left spark plugs for damage, GO to 1051.
wear, carbon deposits and proper air gap.
,
Are the spark plugs and wires OK? No ~ REPLACE or SERVICE
the damaged
component and
RERUN Quick Test.
~

ALL RIGHTS RESERVED

-Coil Failure Test
05 I LEFT SPARK FAULT - CHECK MODULE

OUTPUT

No ~ REPLACE the DIS
Connect diagnostic cable to breakout box. module and RERUN
Quick Test.
Use 2.3L overlay.
vehicle harness connector (Pins 7-12).
Connect a jumper between J55 (IGND S) and
J60 (BAT -).
Connect a jumper between J54 (DPI) and
J55 (IGND S).
If spark was missing from cylinders 1 and 4,
connect LED test lamp between (+) J5 (VBAT D)
and (-) J3 (LC3D). ' .
If spark was missing from cylinders 2 and 3.

connect LED test lamp between (+) J5 (VBAT D)
and (-) J6 (LC4D).
06 I LEFT SPARK FAULT - CHECK LEFT COIL

PACK VBAT
,
Remove jumpers.
No ~ CHECK connectors,
Reconnect diagnostic cable connector to DIS SERVICE or REPLACE
module (Pins 7-12). the harness. RERUN
;- . Quick Test.
Connect LED test lamp between (+) J15 (BAT L)
and (-) J60 (BAT - ).
KeYon.

ALL RIGHTS RESERVED

Conti'nuous Memory Code 18: ,D
Coil Failure Test
07 ILEFT SPARK FAULT-ISOLATE LEFT COIL

PACK
.' Key off. Yes ~ REPLACE the left coil

pack and RERUN
Disconnect HEGO sensor. Quick Test.
Disconnect diagnostic cable connector from the
left coil pack. No ~ GO to losl.
For spark missing from cylinders 1 and 4:
- Connect LED test lamp between (+) J57
(BAT +) and (-) J30 (LC3C).
- Connect LED test lamp between (+) J57
(BAT +) and (-) J28 (LC4C).
Crank the engine.
crank or when running?
,
08 I LEFT SPARK FAULT-CHECK FOR OPEN
Disconnect diagnostic cable connector from DIS Yes ~ GO to 1091.

module (Pins 7-12).
For spark missing from cylinders 1 and 4: No ~ Circuit is open between
the left coil pack and,
- Is the resistance between J3 (LC3D) and the DIS module.
J30 (LC3C) less than 5 ohms? SERVICE harness and
connectors. RERUN
For spark missing from cylinders 2 and 3: Quick Test.
- Is the resistance between J6 (LC4D) and
J28 (LC4C) less than 5 ohms?
..

ALL RIGHTS RESERVED

Coil Failure Test
09 I LEFT SPARK FAULT - CHECK FOR SHORTS
For spark missing from cylinders 1 and 4: Yes ~ Circuit is shorted to

VBAT between the DIS
- Is the resistance between J3 (LC3D) and module and coil pack.
J57 (BAT -) less than 10K ohms? SERVICE harness and
connectors. RERUN
Quick Test.
- Is the resistance between J6 (LC4D) and
J57 (BAT -) less than 10K ohms? No ~ Circuit is shorted to
ground between the
DIS module and coil
pack. SERVICE
harness and
connectors. RERUN
Quick Test.
010 I RIGHT SPARK FAULT - CHECK MODULE

OUTPUT

Install diagnostic cable. and RERUN Quick
Test.
harness (Pins 7-12)
Use 2.3L overlay.
Connect a jumper between J55 (IGNDS) and J60
(BAT -).
- Connect LED test lamp between (-) J18
(RC1 D) and (+) J57 (BAT +).
(RC2D) and (+) J57 (BAT+).
the engine is cranked?

ALL RIGHTS RESERVED

Continuous Memory Code 18: .. D
Coil Failure Test
011 IRIGHT SPARK FAULT-ISOLATE RIGHT COIL

PACK
Key off. Yes ~ REPLACE the right coil

pack. RERUN Quick
Disconnect diagnostic cable connector from the Test.
right coil pack.
For spark missing from cylinders 1 and 4: No ~ GO to 10121.
(RC1C) and (+) J57 (BAT +).
- Connect LED test lamp between J24 (RC2C)
(-) and J57 (BAT +).
Does the LED test lamp blink continuously
when the engine is cranked?
012 I RIGHT SPARK FAULT - CHECK FOR OPEN

module (Pins 7-12). No ~ Circuit is open between
the DIS module and
For spark missing from cylinders 1 and 4: coil pack. SERVICE
- Is the resistance between J18 (RC1D) and harness and
connectors. RERUN
J23 (RC1C) less than 5 ohms?
Quick Test.
- Is the resistance between J 10 (RC2D) and
J23 (RC1C) less than 5 ohms?
013 I RIGHT SPARK FAULT - CHECK FOR SHORTS
Disconnect HEGO sensor. Yes ~ Circuit is shorted to

ground between DIS
For spark missing from cylinders 1 and 4: module and coil pack.
- Is the resistance between J18 (RC1D) and SERVICE harness and
J60 (BAT -) less than 10K ohms? connectors. RERUN
Quick Test.
- Is the resistance between J10 (RC2D) and No ~ Circuit is shorted to
J60 (BAT -) less than 1QK ohms? VBAT between the DIS
Connect diagnostic cable connector to DIS module module and coil pack.
(Pins 7-12). SERVICE harness and
connectors. RERUN
Quick Test.

ALL RIGHTS RESERVED

Continuous Memo~ Code 88: DPI E
Open, IDM Open Or Spout High Test
E1 I ISOLATE SPOUT HIGH
Key off. Yes ~ GO to IE21.

No ~ Spout fault.
Install diagnostic cable. GO to IE31.
Use 2.3L overlay.
Connect LED test lamp between (+) J36 (SPOUT)
and (-) J60 (BAT - ).
engine is cranked or when engine is running?
E2 I ISOLATE DPI OPEN
Using a Neon Spark Tester (D89P-6666-A), Check Yes ~ GO to IE61.

for spark at each left side plug wire with the
engine running. No ~ GO to IE111.
Was spark present at one or more wires?
E3 I SPOUT HIGH -ISOLATE SPOUT TO EEC
Key off. Yes ~ GO to IESI.

Remove spout harness jumper plug from SPOUT
vehicle harness connector. No ~ GO to IE41.
Connect LED test lamp between (-) J60 (BAT - )
and (+) EEC side of SPOUT vehicle harness
connector.
Does LED Test Lamp blink continuously when
engine Is started?
DIS SIDE ~ EEC SIDE
SPOUT INLINE VEHICLE

HARNESS CONNECTOR A127SS-A

ALL RIGHTS RESERVED

E4 I SPOUT HIGH - CHECK FOR SHORT TO VBAT
Key off. Yes ~ Circuit is shorted to

Disconnect BAT + cable. VBAT between EEC-IV
. processor and spout
connector. SERVICE
Is the resistance between J57 (VBAT+) and harness and
the spout vehicle harness connector (EEC ' connectors. RERUN
side) more than 10K ohms? Quick Test.
DIS SIDE ~ EEC SIDE 'No ~ REPLACE processor.

- RERUN Quick Test.
HARNESS CONNECTOR A12755A
,
E5 I SPOUT HIGH - CHECK FOR SHORT TO VBAT

Disconnect diagnostic cable connector from DIS VBAT between DIS
module (Pins 1-6). module and spout
connector. SERVICE
Is the resistance between J57 (BAT+) and the harness and
spout harness connector (DIS side) less than connectors. RERUN
10K ohms? Quick Test.
DIS SIDE ~ EEC SIDE

and RERUN Quick
SPOUT tNL1NE VEHICLE
HARNESS CONNECTOR
Test.
A12755A
,
E6 110M OPEN - CHECK DIS MODULE 10M
OUTPUT
Connect LED Test Lamp between (+) J4 (10M D) Yes ~ GO to IE71.

and,,( -) J60 (BAT -).
Crank or start engine~ No ~ GO to lEal.
Does ,LEQ test lamp blink continuously?
E7 110M OPEN - CHECK 10M CIRCUIT

CONTINUITY ,
Key off. Yes ~ REPLACE processor.

Is the resistance between Test Pin 4 (10M) at RERUN Quick Test.
the EECIV vehicle harness connector and J4
(10M) at the DIS connector less than 5 ohms? No ~ ,10M cir9uit is open
I
between the DIS

module and the
processor. CHECK
connectors, SERVICE
or REPLACE the
Test.

ALL RIGHTS RESERVED

Open, 10M Open Or Spout High Test
E8 110M OPEN -ISOLATE EEC-IV PROCESSOR
Key off.
Yes
REPLACE processor.
.RERUN Quick Test.
Crank engine.
No
GO to IE91.
E9 110M OPEN - CHECK FOR SHORT TO .

GROUND
Key off. Yes ~ 10M circuit is shorted

to ground between DIS
module and processor.
module (Pins 7-12).
CHECK connectors,
Remove the LED test lamp. SERVICE or REPLACE
Is resistance between J4 (10M) and J60 the harness. RERUN
(BAT -) less than 5 ohms? Quick Test.
No ~ GO to IE101.
E10 110M OPEN - CHECK FOR SHORT TO VBAT
Is resistance between J4 (10M) and J57 (BAT+)

less than 5 ohms?
Yes
10M circuit is shorted
to VBAT between DIS
CHECK connectors,
SERVICE or REPLACE
the harness. RERUN
Quick Test.
No ~ REPLACE DIS module.

RERUN Quick Test.
E11 I DPI OPEN-CHECK CONTINUITY
Key off. Yes

GO to IE121. .

Disconnect diagnostic cable connector from DIS No DPI is open betw~en
module (Pins 1-6) the DIS module and
the processor. CHECK
Connect diagnostic cable to breakout box. connectors, SERVICE
Use 2.3L overlay. or REPLACE the
Disconnect EEC-IV processor. . Test.
Is resistance between Test Pin 32 (DPI) at the
EEC-IV vehicle harness connector and J54
(DPI) less than 5 ohms?

ALL RIGHTS RESERVED

E12 I OPI OPEN-CHECK FOR SHORT TO VBAT
Is resistance between J54 (DPI) and J57 Yes ~ OPI is shorted to VBAT
(BAT+) less than 10K ohms? between the DIS
CHECK connectors,
SERVICE or REPLAC~
the harness. RERUN
,
Quick Test. .
No ~ GO to IE131.
E13 I OPI OPEN -ISOLATE EEC PROCESSOR
Connect a jumper between J54 (OPt) and J60 Yes ~ REPLACE processor.
(BAT -) RERUN Quick Test.
i ~AUTION 1
No. ~ REPLACE DIS module.
Do not jumper J54 to VBAT+ or BAT+ or th~ RERUN Quick Test.
DPI circuit in the EEC-IV processor will be
damaged.
Start the engine.
Is there spark at any left plug wire?
, .

ALL RIGHTS RESERVED
2.3L EFI Truck (Dual P1u9) DIS 'Pinpoint

Engine Running Code 18/ F
No Codes and Lack of Power .Test
F1 I CHECK TIMING AT IDLE
Key off. Yes ~ Refer to Shop Manual,

Compact Truck Group
Install timing light. 03.
Engine running at normal operating temperature.
'Transmission out of gear. No ~ GO to IF21.
Check the timing.
Is the timing greater than 19 BTDC?
F2 I TIMING FAULT - CHECK SPOUT FUNCTION

and RERUN Quick
Test. If problem still
Install diagnostic cable. exists, REPLACE the
processor. RERUN
Quick Test.
Use 2.3L overlay.
Disconnect diagnostic cable connector from DIS No ~ GO to IF31.
module (Pins 1-6).
and (-) J60 (BAT - ).
crank or engine running?
F3 I SPOUT FAULT -ISOLATION
Key off. Yes ~ GO to IF61.

Remove SPOUT harness jumper plug from SPOUT
vehicle harness connector. No ~ GO to IF41.
Connect diagnostic cable connector to DIS module
(Pins 1-6).
Connect LED test lamp between (-) J60 (BAT - )
and (+) EEC side of spout vehicle harness
connector.
Does LED Test Lamp blink continuously when
engine Is started? .
Connect diagnostic cable connector at DIS module
(Pins 1-6).
DIS SIDE ~ EECSIOE


ALL RIGHTS RESERVED
2.3L EFI Truck (Dual Plu9) DIS Pinpoint

No Codes and Lack of Power Test
F4 I SPOUT FAULT - CHECK CONTINUITY
Key off. Yes ~ GO to IFSI.

No ~ Circuit is open between
Is the resistance between Pin 36 (SPOUn at the spout connector
the EEC-IV vehicle harness connector and the and processor.
EEC side of the spout harness connector less SERVICE harness and
than 5 ohms? connectors. RERUN
Quick Test.
DtSSIDE ~ EECStDE
F5 ICHECK SPOUT FOR SHORT CIRCUIT FOR

SHORT TO GROUND
,

ground between the
Disconnect EEC-IV processor. processor and SPOUT
Is resistance between J60 (BAT -) and the cOJ1nector. SERVICE as
necessary. RERUN
EEC side of the spout connector less than
Quick Test.
10K ohms?
DtSSIDE ~EECS'DE No ~ REPLACE the

processor. RERUN
SPOUT INLlNE VEHICLE Quick Test.
HARNESS CONNECTOR A127S5-A
F6 I CHECK SPOUT CIRCUIT CONTINUITY
Key off. Yes' ~ GO to IF71.

Is the resistance between J36 (SPOUT) and
the DIS side of the spout connector less than No ~ Circuit is open between
the DIS module and
5 ohms?
SPOUT connector.
SERVICE harness and
connectors. RERUN
Quick Test.

ALL RIGHTS RESERVED
2.3L EFI Truck (Dual Plu9) DIS Pinpoint

No Codes and Lack of Power Test
F7 I CHECK SPOUT CIRCUIT FOR SHORT

TO GROUND

ground between the
Disconnect diagnostic cable connector from DIS DIS module and
module (Pins 1-6) SPOUT connector.
SERVICE harness and
Is resistance between J60 (BAT -) and J36
connectors. RERUN
(SPOUT) less than 10K ohms? Quick Test.

and RERUN Quick
Test.

ALL RIGHTS RESERVED

Misfire Under Load G
(Bad Plugs, Wires or Short to Ground) Test
PRELIMINARY NOTES
system.
CHECKOUT
. .
.. Be certain the battery is fully charged.
EQUIPMENT
DIS Adapter Rotunda (Rotunda 007-00044).

ALL RIGHTS RESERVED


essential that the calibration of your engine analyzer be maintained. Refer to your
equipment manual. If this is not available, an estimate of the calibration can be made
by connecting the spark tester (081 P-6666-A or equivalent) to a properly operating
ignition system and measuring the firing voltage of the spark tester only. Do not
include the firing voltage of the rotor-to-cap gap. The spark tester firing voltage
should be approximately 28 KV.


ALL RIGHTS RESERVED

(Bad Plugs, Wires o~ Short to Ground) Test

value of spark values for a properly
20
plug firing operating ignition
15- voltage: 15 KV system.
or less with
10- . evenness of
KV . spark plug firing
5-
.~. ~ voltage: 5 KV
or less
~., ~,
0- ,- l' ~
5
1 3 4 2
CYLINDER A12753-A

20
value of spark cylinders:
plug firing
15- voltage: greater CHECK ignition coil
-
10-
than 15 KV
with evenness
wires for proper
installation in coil.
KV - of spark plug
) lj
5 ~ firing voltage: 5 MEASURE resistance
-
o- ~ 1.r f,--
KV or less of ignition wires.
.. REPLACE if greater
5
than 7,000 ohms per
1 3 4 2 foot.
CYLINDER A12754A
,
Wide spark plug
gaps - all cylinders
(usually from worn
mileage).

ALL RIGHTS RESERVED


20
spark plug firing some cylinders:
. voltage: greater
15_ than 5 KV Wide spark plug gap(s)
or worn electrode(s).
10-
KV
5-

~ ~
o.Lt .. ... II
.
,~
5
, 3 4 2
CYLINDER A12752A

20
high spark plug firmly connected.
firing voltage in
15- one or more Disconnected spark
cylinders plug wire(s).
10-
KV Wide spark plug gap(s).
5-
0-
.
~ O'
l Lc
~ Open plug wire(s).
5
1 3 4 2
CYLINDER A12751-A

ALL RIGHTS RESERVED
Ignition Systems, Timing Procedures and Diagnosis 13119'

Consistently low ~ Fouled spark plug(s).

20
spark plug firing
sloping spark gap(s).
15-
line in one or
10- more cylinders Spark plug wire(s)
KV grounding on engine.
5- Inspect for damage.
o-
N,
w- f'" .- ~
5
1 3 4 2
CYLINDER A1215().A
..
..

ALL RIGHTS RESERVED

H
No Codes - Intermittent Diagnosis Test
H1 I
Talk to owner. ~ Symptoms.
H2 1
Review vehicle service history. ~ Number of previous
REPAIRS and
components
REPLACED.
H3 1
Will engine start? Yes ~ GO to Step IH41.
No ~ GO to Step IA11.
H4 TSHAKE TEST
Engine at idle, Raise hood, Shake wiring harness Yes ~ SERVICE wiring
and Pull wires at connectors for ignition harness or connector.
components. CHECK DIS Mounting
Does engine quit? Bolts.
No ~ GO to Step IHsi .
H5 I TEMPERATURE CHECK
Engine at idle, close hood, AIC ON, blower on Yes ~ GO to Step IH91 .
medium speed. Allow engine to run for 15
minutes.
No ~ GO to Step IH61 .
Does engine quit?
H6 I HOT SOAK CHECK
Engine off, Hood closed, hot soak for 10 minutes. Yes ~ GO to Step IH71 .
H7 1 HOT SHAKE CHECK

Engine at idle, Raise hood, Shake wiring harness Yes ~ SERVICE wiring
and Pull wires at connectors for ignition harness or connector.
components.
Does engine quit? No ~ GO to Step IHsl.

ALL RIGHTS RESERVED

H
H8 I ROAD CHECK
Road test. Yes ~ GO to Step IH91 .

Does engine quit?
No ~ Test complete.
;
H9 I ROAD SHAKE CHECK
Raise hood, Shake wiring harness, Pull wires. at Yes ~ SERVICE wiring
connectors, Separate and Reconnect connectors harness or connector.
for ignition components.
Does engine quit?

ALL RIGHTS RESERVED
IGNITION SYSTEM
DIAGNOSTIC
PROCEDURE
(DIS)
3.0L SEFI SHO AND
3.8L SEFI
SUPERCHARGED

ALL RIGHTS RESERVED
Index: 3.0L SEFI SHO and 3.8L SEFI SC DIS
NOTE: Start all diagnostics with Section 14 (EEC-IV Quick Test) first. The tests in this
section are dependent on results from tests conducted in Section 14.
Subject Page
Preliminary Checkout, Equipm~nt and Notes : 13-124

DIS Diagnostic Cable 13-125
3.0L SEFI SHO and 3.8L SEFI SC DIS Module and Pin-Out. 13-126
3.0L SEFI SHO DIS Wiring Schematic 13-127
3.8L SEFI SC DIS Wiring Schematic 13-128
DIS Schematic and Breakout Box Overlay Acronyms 13-129
Camshaft and Crankshaft Sensor Description 13-130
3.0L SEFI SHO and 3.8L SEFI SC DIS System Description 13-131
3.0L SEFI SHO and 3.8L SEFI SC DIS Block Diagram 13-132
3.0L SEFI SHO and 3.8L SEFI SC DIS Waveforms 13-133
3.0L SEFI SHO DIS Component Location " 13-134
3.8L SEFI SC DIS Component Location 13-135
3.0L SEFI SHO and 3.8L SEFI SC DIS Pinpoint Test Diagnostics 13-136

ALL RIGHTS RESERVED
13124 Ignition Systems, Timing 'Procedures and Diagnosis
CHECKOUT
Examine all wiring harnesses and connectors for insulation. damage, burned, overheated,
damaged pins, loose or broken conditions. Check sensor shield connector. Make sure DIS
module mounting screws are tight.
DIS Diagnostic Cable (Rotunda 007-00044) (refer to Figure 1).
Spark Tester, Neon bulb type Special Service Tool (D89P-6666-A).
Volt/Ohm Meter (Rotunda 014-00407 or equivalent).
Spark Tester, Gap type (Special Service Tool D81 P-6666-A). A spark plug with a broken
Inductive Timing Light (Rotunda 059-00006 or equivalent). Do not use "advance knob" if
timing light has one (it will not work correctly with DIS Ignition System).
EQUIPMENT (Recommended)
Dis Module Tester (DMT) Rotunda 007-00071. This tester contains 12 LEDS, 12 Test Jacks
and a built-in interface cable that allows the tester to monitor all DIS module signals.
DIS Coil/Sensor Tester (CST) Rotunda 007-00072. This tester is similar to the DIS Module
Tester (DMT) except it allows monitoring of signals at the sensor and coils.
circuit and may cause erroneous measurements or improper DIS/EEC-IV operation. (ie.,
engine stall).
NOTES
volt. Also BAT( +) readings mean any value that falls within a range of BAT + to 2 volts less
than BAT +. .
battery lead or cast iron on the engine. BAT(+) means the positive battery cable at the
battery.
the plug boot. Very weak flashing may be caused by a fouled plug.

ALL RIGHTS RESERVED
DIS Diagnostic Cable
(INPUT MODULE TEE) (OUTPUT MODULE TEE)
2.3L LEFT COIL

DIS MODULE
TEE (NOT USED)
2.3L RIGHT COIL

TEE (NOT USED)
CAMSHAFT
SENSOR
TO SENSOR SHIELD
(SHIELD TEE) 3.0L/3.8L
COIL PACK
(NOT USED)
WARNING: DO NOT
CONNECT EEC PROCESSOR
TO THIS CONNECTOR
BREAKOUT
BOX
A9264-C
Figure 1 3.0L SEFI SHO and 3.8L SEFI SC DIS Hook-Up

ALL RIGHTS RESERVED
3.0L SEFI SHO and 3.8L SEFI SC DIS

Module and Pin-Out
0 0
1
2
MOTORCRAFT
DIS
12
11
.
~D
5
0
10
9
8
1
UP
6 ,- - - - - - - - - - - - - - - , - -- 7 "l-
I I
I
d 0
NOTE PIN 7 (ION GND) IS CONNECTED INTERNALLY

TO THE BOTTOM DIS MODULE MOUNTING HOLES.
THIS IS THE SOURCE OF IGND.
A9265-B
Figure 2 3.0L SEFI SHO and 3.8L SEFI se DIS Module and Pin-Out
3.0L SEFI SHO

PIN # and
3.8L SEFI SC
1 VBAT
2 CIO
3 -
4 PIP In
5 SPOUT
6 -
7 IGNO
8 COIL 1
9 COIL 3
10 -
11 COIL 2
12 10M

ALL RIGHTS RESERVED
~
~
::;
0'
~ rr----- "I .\ CID 24 ~ ::J
<=
CRANKSHAFT
SENSOR PIP 56 UJ
1''''''--''--
<ti
(,.)
~
(3.0L)
I
I
\ I
I SPOUT 3.
IGNG~
., ( TO
EECIV
PROCESSOR
r-
(I}
-
'<
(I)
CD
3
~
I r--------
I
IDM4
m !b
~
::n
I
I I
i
CASE GND
....
tTl -t
3'
5'
I (I} co
I
~ I :c ...
~
o
~
CJj
[1I/ll r------,
I
I
", __I
I
I IGNITION COIL
(3.0L)
o
o
o
n
CD
a.
...
c:
....
SPOUT IN-LINE
CONNECTOR CD
~ I \ en
5'
CQ
~
:::J-
~
.Q)
(SHIELD)
\
I \
J
I'-..J
--,
TO BAT+
~
1 T
-
(I}
........~
....
I
::J
a.
C
m-
co
::J
\ I ::s o
~ en
()
o
z
\L....:.-, ~
6 6 6
61 [5 1 ['j 1 ~
G ~ ~ CD
G
=
(I}
en
in
I
g
... 1- ' -
1....
(C2D)
g.
~
(C3D) a
(PIP D)
(SPOUT)
(C1D) ........
C
n
PINS 1.6 . DIS MODULE PINS 7-12
BAT +
d
EEC POWER VBAT
RELAY
NOTE: CONNECTORS ARE SHOWN LOOKING INTO THE WIRING HARNESS.

IGN GND IS A LOW CURRENT REFERENCE FOR THE EEC-IV PROCESSOR AND DIS MODULE.
IT IS CONNECTED TO BATTERY NEGATIVE (GROUND) VIA THE DIS MODULE METAL BASE
PLATE. PROPER SYSTEM OPERATION DEPENDS ON A LOW RESISTANCE PATH TO GROUND.
ALL RIGHTS RESERVED
A12746-B
~
c,,)
I
~
....,
Ii\)
~
~
~
I\)
~ (A) C
c: CRANKSHAFT
go
Q3
~
SENSOR
(3.8L) rr----- C/D24
PIP-56
r-
1 1 .---- (I)
~ SPOUT 36 TO
Q:)
r-- I
. EEC-IV
rrJ
....
IGN GND 16 PROCESSOR
en r-------- ."
I IDM 4
.~
...... I (I)
~ en
n. ~
I
I
'7 CASE GND n
~ ~ c
~
~.
c=. ~ I
-- I IGNITION COIL
....
(I)
~. ,, __I SPOUT IN-LINE
CONNECTOR
(3.8L)
g I \
\ I
-..., TO BAT + TO BAT ...........~
~
~
,
I'-.J
\
\L_,
\ I
~ ~ ~
61
6 6 6
1. 1~
=='
(I)
n
C
::::I
::;:
G. :r
ft)
c)"
::::I
I
a en
1<1-'-
(C2D) f
....
P+ -
'<
UJ
CD
3
(C3D)
n ~
-4
(C1D)
3"
S-
ea
_____ "U
~
DIS MODULE _ _ _ _ o
BAT + d o--j.~V;;:::B-;';AT~~~~===-----------~~--=------------------.
PINS 16 PINS 7-12 n
CD
Q.
c
EEC POWER ~
RELAY CD
UJ
NOTE: CONNECTORS ARE SHOWN LOOKING INTO THE WIRING HARNESS. I
IGN GND IS A LOW CURRENT REFERENCE FOR THE EECIV PROCESSOR AND DIS MODULE. ::::I
ALL RIGHTS RESERVED
IT IS CONNECTED TO BATTERY NEGATIVE (GROUND) VIA THE DIS MODULE METAL BASE Q.
PLATE. PROPER SYSTEM OPERATION DEPENDS ON A LOW RESISTANCE PATH TO GROUND. A12747B C
i
ea
::::I
o(I)
iii"
Ignition Systems, Timing Procedures and Dlagno~ls 13-129
DIS Schematic and Breakout Box Overlay Acronyms
There is a logic to the names on the Schematic and Overlays for the DIS DIAGNOSTIC
HARNESS that will help you. .
DIS Acronyms
PIP . Profile Ignition Pickup (Crankshaft Sensor signal).
CIO Cylinder IDentification.
SPOUT SPark OUT (EEC Spark control signal).
BAT+ Battery Positive.

. '. d
BAT- Battery Negative.
IGGND low current ground reference.
OPI Dual Plug Inhibit (High - Right Plugs fire; low - Both Sides fire).
C1, C2, C3 Coil Drive (For Coils 1, 2, and 3).

Overlay Designators
that tells you where the measurement is being taken. The key to these letters is:
Suffix "0" is at the .01S Module.
"S" or "PS" or "CS"

Suffix is at the sensor, "P" for PIP, "C" for CIO.,
Suffix "EEC" is at the signal source (the sensor).
VBAT PS means VBAT at the PIP Sensor.
VBAT 0 means VBAT at the DIS Module.

ALL RIGHTS RESERVED
Camshaft and Crankshaft Sensor Description
The Camshaft and crankshaft sensors used on the 3.0L SHO and 3.8L SC vehicles are digital
Hall devices (Figure 5). The 3.0L SHO Camshaft sensor is located on the right end of the
rear cylinder head close to cylinder 1. In the 3.8L SC, the Camshaft sensor is in the location
normally used for the distributor. The Camshaft sensor is the same in both cases but the
mounting adaptor is different. A rotary vane cup (or wheel), made of ferrous metal (Figure 6),
is used to trigger the Hall effect switch located in each of the sensors. The camshaft cup has
one tooth and is driven by the camshaft. The signal from the Camshaft sensor has one
positive-going edge once every two crank revolutions (one cam revolution). The crankshaft cup
has three teeth and the Crankshaft sensor generates three positive (PIP) edges every
revolution of the crankshaft.
When the window of the vane cup is between the magnet and Hall effect device, a magnetic
flux field is completed from the magnet through the Hall effect device and back to the magnet
(Figure 7), the output signal will be low (0 volts). However, when the vane tooth moves into
the gap between the Hall effect device and the magnet, the flux lines are shunted through the
vane and back to the magnet (Figure 8) and the output will change from a low to high
(VBAT).
HALL EFFECT
DEVICE .
A9269-A
A9268-A
Figure 5 Hall Effect Device Figure 6 Rotary Vane Cup - CAM Sensor
HALL PERMANENT
PERMANENT EFFECT MAGNET
MAGNET DEVICE
HALL EFFECT
DEVICE
OUTPUT = 0 VOLTS A9270-A OUTPUT = VBAT A9271-B
Figure 7 Magnetic Flux Field Figure 8 Hall Effect Device Response to

Vane

ALL RIGHTS RESERVED
191111ion Systems, Timing Procedures and Diagnosis 13-131

System Description
The 3.0L SEFI SHO and 3.8L SEFI SC Distributorless Ignition System (DIS) (refer to Figure 9)
consists of a crankshaft mounted Hall (PIP) Sensor, a camshaft driven Hall (CID) sensor, a 6
tower DIS coil pack, and a DIS ignition module.
The DIS eliminates the distributor by using "multiple ignition coils. Each coil fires two spark
plugs at the same time. The plugs are paired so that as one fires during the compression
cycle the other fires during the exhaust stroke. The next time the coil is fired the plug that
was on exhaust will be on compression and the one that was on compression will be on
~xhaust (the spark in the exhaust cylinder is wasted but little of the coil energy is lost). Three
coils are mounted together in a "coil pack". The coil pack has three tach wires, one for each
coil. The crankshaft sensor is a digital output Hall device (PIP) that responds to a rotating
metallic vane mounted on the crankshaft damper assembly.
The 3.0L SHO DIS CID signal is generated by a Hall device mounted at the end of the rear
camshaft. The vane cup has one tooth and is driven by the camshaft. The 3.8L SC DIS
camshaft sensor is a Hall device but it is mounted in the normal distributor location.
The PIP output is a 50 percent duty cycle signal that provides base spark timing information.
, The CID signal output is also a 50 percent duty cycle signal and is required so that the DIS
module knows which coil to fire and for fuel timing in the EEC-IV processor. CID is high
(VBAT) half of the cam revolution (180 degrees) and low the other half (refer to Figure 10).
The EEC-IV processor determines spark angle using the PIP signal to establish base timing.
Spout is sent from the EEC-IV proces~or to the DIS module and' serves two purposes: the
leading edge fires the coil and the trailing edge controls the dwell time. This feature is called
CCD or computer controlled dwell.
The Ignition Diagnostic Monitor (IDM) is an output from the DIS module that provides
diagnostic information concerning the ignition system to the EEC-IV processor for self-test and
is also the input signal for the vehicle tachometer. If the CID circuit fails and an attempt to .
start the engine is made, the DIS modUle will randomly select one of the three coils to fire. If
hard starting results, turning the key off and then cranking again will result in another "guess. II
Several attempts may be needed until the proper coil is selected allowing the vehicle to be
started and driven until repairs can be made. The Failure Mode Effects Management (FMEM)
system attempts to keep the vehicle driveable in spite of certain EEC-IV system failures that
prevent the EEC-IV processor from providing spark angle or dwell commands. The EEC-IV
processor opens the SPOUT line and the DIS module fires the coils directly from the PIP
input. This results in a fixed spark angle of 10 degrees and fixed dwell.
The 3.0L SEFI SHO and 3.8L SEFI SC DIS component locations are shown in Figures 11
and 12.

ALL RIGHTS RESERVED

Block Diagram
IGNGND
PLUGS
CID +
217 r-+ ......;1~ ~h
CID 8 COIL 1 5 -
"'-tl-----=-t t----itl
3 +
CAMSHAFT SENSOR
DIS 1"-'4-----... .............
MODULE
11 t------.....
COIL 2
4-I
PIP
COIL
CRANKSHAFT SENSOR PACK
SPOUT
10M
4 36
C/O 24
PIP
IGNGND 56
16
EEC-IV
PROCESSOR
A9272B
Figure 9 3.0L SEFI SHO and 3.8L SEFI SC Distributorless Ignition System (DIS)

ALL RIGHTS RESERVED
3.0L SEFI SHO and 3.8L SEFI SC DIS Waveforms
Timing Diagram
TDC TDC
PIP
I
CID
I.
I
~~---r
SPOUT
I I
I I
I I FIRE '1 FIRE
_.._ IrlrCOIL2!t-1~coIIL2 "
COIL CURR~
(PIN 11) I I
IL:
,I
' i I I
r r...
I I FIRE I 'FIRE
COIL cURR_E_NT ?_L_3~-------oInr-C-~-'L-3......r---
y--y-_c......
(PIN 9) i I
COIL CURR_EN_T
(PIN 8)
~ hr FIRE
COIL 1
I FIRE
nrCOIL 1
10M
(PIN 12)
PIP
SIGNAL
THIS View SHOWS THE VANE CUP

"TDC I AS INSTALLED ON THE ENGINE. A9273-B
Figure 10 3.0L SEFI SHO and 3.8L SEFI se DIS Waveforms

ALL RIGHTS RESERVED
3.0L SHO DIS Component Location
/
7~
~~ -COIL PACK
/
FRONT OF VEHICLE
/'
A9274-8
Figure 11 3.0L SHO DIS Component Location

ALL RIGHTS RESERVED
3.8L SC DIS Component Location

.1
COIL PACK
CAMSHAFT SENSOR
CRANKSHAFT
SENSOR
Figure 12 3.8L SC DIS Component Location

ALL RIGHTS RESERVED
3.0L SEFI SHO and Pinpoint

3.8L SEFI SC DIS Index
f CAUTION I
A 12 Yolt Test Lamp should not be used to test circuit signals. It will load the circuit
and may cause erroneous measurements or improper DIS/EEC-IV operation (Ie., engine
stall). .
INote I
Use YOM or LED test lamp circuit (Figure 1) in the following pinpoint test procedures. The
LED test lamp is more convenient and faster to use.
If a YOM is used, correct test lead polarity must be followed. The red lead is (+) positive
and the black lead is (-) negative.
To check PIP or CID the engine is "Bumped" with the starter while watching the voltmeter.
Both the CID and PIP signals are digital and should switch between VBAT and Ground as the
engine turns. To see the signal change using the YOM the engine must be turned in very
short bursts.
If an LED test lamp is used, wire the LED as shown below:
R1 RADIO SHACK 271-019 470/\
R2 RADIO SHACK 271-019 470/\
THE LED TEST LAMP IS "ON" IF EITHER THE RED OR GREEN

LED IS LIT. A12748A
Figure 1

ALL RIGHTS RESERVED

3.8L SEFI SC DIS Index
These diagnostics were written to catch "Hard faults";

intermittent failures will be difficult or impossible to
diagnose using these procedures.
Engine No Start: ......... GO to IA11.
......
- With Continuous Memory Code 14 ...... GO to IA31.
Engine Runs With:
- Continuous Memory Code 18 ~ GO to (jjJ.
- Continuous Memory Code 19 ~ GO to IC11.
......
- Continuous Memory Code 45, 46 or 48 ...... GO to 1011.
- Hard to start ~ []I].
GO to
- Continuous Memory Code 49
....
..... GO to [I].
- Engine Running Code 18 ~ GO to [I].
- Misfire under load ~ GO to IG11.
......
- Intermittent stall ..... GO to [HI].
- -.

ALL RIGHTS RESERVED

3.8L SEFI SC DIS A
No Start Test
A1 I PERFORM EEC-IV QUICK TEST
Refer to Section 14 and perform EEC-IV Quick Yes ~ SERVICE any EEC-IV
Test. code first. If still no
start, GO to IA21 .
Are any service codes (KOEO, KOER or
Continuous Memory) present?
No ~ GO to IA21.
Using a Neon Bulb Spark Tester (D89P-6666-A), Yes ~ GO to IA31.

check for spark at all spark plug wires while
cranking.
No ~ GO to IASI.
Was spark present on ALL spark plug wires
and consistent (one spark per crankshaft
revolution)?
A3 I CHECK PIP EEC AT CRANKSHAFT SENSOR

No ~ REPLACE crankshaft
sensor and RERUN
Use 3.0L/3.8L overlay. Quick Test.
Connect LED test lamp between (+) J33
(PIP EEC) and (-) J60 (BAT - ).
Crank engine.
crank?
A4 ICONTINUITY
CHECK PIP EEC AND IGND TO EEC-IV
Key off. Yes ~ GO to Section 17,

Disconnect EEC-IV processor from vehicle harness Pinpoint Test
connector. Step IA11.
module (Pins 1-6 and Pins 7-12). No ~ SERVICE open circuit.
CHECK connectors,
Measure resistance between Test Pin 56 (PIP) of SERVICE or REPLACE
the EEC-IV vehicle harness connector and J33 harness. RERUN Quick
(PIP EEC). Test.
Also measure the resistance between Test Pin 16
(IGN GND) of the EEC-IV vehicle harness
connector and J55 (IGND PS).
Are both measurements less than 5 ohms?

ALL RIGHTS RESERVED

3.8L SEFI SC DIS A
No Start Test
A5 I DETERMINE MISSING SPARK COMBINATION
Was spark missing from BOTH cylinder 1 and Yes ~ GO to IA71.

5 plug wires?
or No ~ GO to IA61.
Was spark missing from BOTH cylinder 2 and
6 plug wires?
or
Was spark missing from BOTH cylinder 3 and
4 plug wires?
A6 I CHECK PLUGS AND WIRES
Check spark plug wires for insulation damage, Yes ~ REINSTALL P1IUgj and
looseness, shorting or other damage. wires. GO to A7 .
, carbon deposits and proper plug gap. No ~ SERVICE or REPLACE
Are spark plugs and wires OK? damaged component.
RERUN Quick Test.
A7 I CHECK DIS MODULE VBAT
Install diagnostic cable. Yes ~ GO to IASI.

Use 3.0L/3.8L overlay. No ~ CHECK connectors,
SERVICE or REPLACE
Connect LED test lamp between (-) J2 harness. RERUN Quick
(IGND D) and (+) J5 (VBAT D). Test.
Keyon.
A8 I CHECK DIS MODULE IGNITION GROUND

Measure resistance between J60 (BAT -) and
J2 (IGND D). No ~ GO to IA91.
Is resistance less than 5 ohms?
A9 I CHECK DIS MODULE MOUNTING SCREWS
Check DIS module mounting screws for corrosion Yes ~ REPLACE DIS module.
or looseness. . RERUN Quick Test.
Are mounting screws clean and. tight?
No ~ CLEAN, REPLACE or
TIGHTEN mounting
screws. RERUN Quick
Test.

ALL RIGHTS RESERVED
3.0L SEFI SHO and 'Pinpoint

3.8L SEFI SC DIS A
No Start Test
A10 I CHECK ALL COIL PACK CIRCUITS
Key on. Yes ~ GO to IA1SI.

Connect LED test lamp between three pairs of
Test Jacks given below. Note if LED test lamp is No ~ GO to IA11/.
on or off each time.
Check between (+) J3 (C1 D) and (-) J6D
(BAT -).
Check between (+) J18 (C2D) and (-) J6D
'(BAT -).
(BAT -).
Was LED test lamp on for all three checks?
A11 I ISOLATE DIS MODULE SHORT(S)
Key off. Yes ~ REPLACE the DIS

module. RERUN Quick
Disconnect diagnostic cable connector from DIS Test.
module (Pins 7-12).
Connect a jumper wire between J2 (IGND D) and No ~ REMOVE jumper wire.
J6D (BAT -). GO to IA121.
Repeat test procedure in Test Step IA10 I .
Was LED test lamp on for all three checks?
A12 I CHECK COIL PACK VBAT C

Reconnect diagnostic cable connector to DIS
module (Pins 7-12). No ~ CHECK connectors,
SERVICE or REPLACE
Connect LED test lamp between (+) J7 harness. RERUN Quick
(VBAT C) and (-) J6D (BAT -). Test.
Key on.

ALL RIGHTS RESERVED
Ignition Systems, Timing Procedures -and Diagnosis 13-141

3.8L SEFI SC DIS A
No Start Test

..
A13 I CHECK IGNITION COIL CIRCUIT
Key on. Yes ~ CHECK connectors,

Connect the LED test lamp between three pairs SERVICE or REPLACE
of test jacks given below. Note if LED test lamp harness. RERUN Quick
is on or off for each one. Test.
For 3.0L SEFI SHO:
- Check between (+) J12 (C1C) and (-) J60
No ~ GO to IA14/.
(BAT -).
j
(BAT -).
(BAT -). . .
For 3.8L SEFI SC:
. (BAT -).
(BAT -).
- Check between (+) J1,4 (C1 C) and (-) J60
(BAT -). "
- Was LED test lamp on for all three check~?
A14 I ISOLATE HARNESS SHORTS
Key off. Yes ~ REMOVE jumper wire.

Disconnect diagnostic cable connector from coil CHECK connectors,
pack. SERVICE or REPLACE
Connect a jumper between J57 (BAT+) and J7 . Test.
. (VBAT C).
Repeat test procedure in Test Step 1A131 .
No ~ Remove jumper wire.
Was LED test lamp on for all three checks? REPLACE coil pack.
RERUN Quick Test.
A 15 I CHECK PIP IN TO DIS MODULE
Connect LED test lamp' between (+) J32 (PIP D) Yes ~ GO to IA161.
and (-) J60 (BAT - ).
Does LED test lamp blink when engine is No ~ GO to IA221.
cranked?
A16 I CHECK SPOUT AT DIS MODULE
Connect LED test lamp between (+) J36 (SPOUT) Yes ~ GO to IA171.
and (-) J60 (BAT - ).
Does LED test lamp blink when engine Is No ~ GO to IA191.
cranked?

ALL RIGHTS RESERVED

3.8L SEFI SC DIS A
No Start . Test
A17 I CHECK DIS MODULE COIL DRIVERS
Connect LED test lamp between each of three Yes ~ REPLACE coil pack.
pairs of test points given below. Note if lamp R~RUN Quick Test.
blinks continuously for each during crank.
Check between (+) J3 (C1 D) and (-) J6D No ~ GO to IA1SI.
(BAT -).
(BAT -).
(BAT -).
Did LED test lamp blink during all three
checks?
A1SIISOLATE COIL PACK FROM SYSTEM
Key off. Yes ~ CHECK connectors,

Disconnect diagnostic cable connector from coil SERVICE or REPLACE
pack vehicle harness connector. harness. RERUN Quick
Test.
Connect the LED test lamp between each of
three pairs of test points given below. Note if
lamp is on for each one with key on. No ~ REPLACE DIS module.
Check between (+) J3 (C1 D) and (-) J6D RERUN Quick Test.
(BAT -).
(BAT -).
(BAT -).
Was any LED test lamp on?
A1911S0LATE EEC-IV PROCESSOR FOR SPOUT
FAULT
Key off. Yes ~ Processor is shorting

Disconnect EEC-IV processor. SPOUT. REPLACE
Connect the LED test lamp between (+) J36 processor.
(SPOUT) and (-) J6D (BAT -).
Does LED test lamp blink continuously while No ~ GO to IA201.
engine is cranked?
A20 I CHECK SPOUT CIRCUIT FOR SHORT TO VBAl
Key off. Yes ~ Spout short to VBAl.

Disconnect diagnostic cable connector from DIS CHECK connectors,
module (Pins 1-6). SERVICE or REPLACE
Connect LED test lamp between (+) J36 (SPOUn
Test.
and (-) J6D (BAT - ).
Keyon.
No ~ GO to IA211.

ALL RIGHTS RESERVED
3.0L SEFI SHO and' Pinpoint

3.8L SEFI SC DIS A
No Start Test
TEST STEP RESULT ,ACTION TO TAKE
A21 ICHECK SPOUT CIRCUIT FOR SHORT TO

GROUND
Connect LED test lamp between (-) J36 Yes ~ Spout short to ground.
(SPOUT) and (+) J57 (BAT +). CHECK connectors,
SERVICE or REPLACE
Key on.
Is LED test lamp on? Test.

RERUN Quick Test.
A22 I ISOLATE DIS MODULE PIP
Key off. Yes ~ REPLACE, DIS module.

Disconnect diagnostic cable connector from DIS RERUN Quick Test.
module (Pins 1-6).
Connect LED test lamp between (+) J32 (PIP D) No ~ GO to 'IA231.
and (-) J60 (BAT-).
engine Is cranked?
A23 I CHECK SENSOR VBAT

Reconnect Diagnostic Cable connector to DIS
module (Pins 1-6). No ~ CHECK connectors,
Connect LED test lamp between (+) J56 SERVICE or REPLACE
(VBAT PS) and (-) J2 (IGND D). harness. RERUN Quick
Key on. Test.
A24 I CHECK SENSOR IGNITION GROUND
Key off. Yes ~ GO to IA2SI.

Measure resistance between J55 (IGND PS) and
J2 (IGND D). : No ~ CHECK connectors,
Is resistance less than 5 ohms? SERVICE or REPLACE
'. ~
.. Test.
A25 I CHECK PIP S AT CRANKSHAFT SENSOR'
Connect LED test lamp between (+) J35 (PIP S) Yes ~ CHECK connectors,
and (-) J2 (IGND D). SERVICE or REPLACE
Does LED test lamp blink continuously when harness. RERUN Quick
engine is cranked? Test.
No ~ GO to IA261.

ALL RIGHTS RESERVED

3.8L SEFI SC DIS A
No Start Test
A26 I CHECK PIP S FOR SHORTS TO GROUND
Key off. Yes ~ PIP S is shorted to

ground be~een sensor
Disconnect diagnostic cable connector from and DIS module.
crankshaft sensor. CHECK connectors,
Disconnect diagnostic cable connector from DIS SERVICE or REPLACE
module (Pins 1-6). harness. RERUN Quick
Test.
Connect LED test lamp be~een (-) J35
(PIP S) and (+) J57 (BAT +).
No ~ GO to JA271.
Key on.
A27 I CHECK PIP S FOR SHORTS TO VBAT
Connect LED test lamp be~een (+) J35 (PIP S) Yes ~ PIPSis shorted to
and (-) J60 (BAT-). VBAT be~een sensor
and DIS module.
Key on. CHECK connectors,
Is LED test lamp on? SERVICE or REPLACE
Test.
No ~ GO to IA2SI.
A28 I CHECK PIP EEC FOR SHORT TO GROUND
Key off. Yes ~ CHECK connectors,

SERVICE or REPLACE
Disconnect EEC-IV processor from vehicle harness. RERUN Quick
harness. Test.
Connect LED test lamp be~een (-) J33
(PIP EEC) and (+) J57 (BAT +). No ~ GO to IA291.
Key on.
A29 I CHECK PIP EEC FOR SHORTS TO VBAT
Connect LED test lamp be~een (+) J33 Yes ~ CHECK connectors,
(PIP EEC) and (-) J60 (BAT - ). SERVICE or REPLACE
Key on. Test.
No ~ GO to IA301.

ALL RIGHTS RESERVED
3~OL SEFI SHO and

3.8L SEFI SC DIS 'I Pinpoint
Test
I A
No Start
L....- ---J L....- --'
A30 I CHECK CRANKSHAFT VANE
Does crankshaft vane move through sensor air Yes ~ REPLACE crankshaft
gap when engine Is cranke.d? sensor. RERUN Quick
Test.
No ~ Refer to Engine Shop

Manual Group.

ALL RIGHTS RESERVED
3.0L SEFI SHO and 3.8L SEFI SC DIS Pinpoint

Continuous Memory Code 18: IDM Failure Or CID
Continuous Memory Code 49: Spout IDM Error Test
81 I VERIFY ERRATIC CRANK
Is vehicle hard to start (i.e., requires more Yes ~ GO to 1821.

than one attempt to start andI or cranking
speed erratic)? No ~ GO to IB51.
82 I CHECK - CID AT DIS MODULE
Key off. Yes ~ REPLACE DIS module.

RERUN Quick Test.
Connect diagnostic cable to breakout box. No ~ GO to -IB31.
Use 3.0L/3.8L overlay.
Connect the LED test lamp between (+) J51 (CID
D) and (-) J60 (BAT - ).
engine is cranked or started?
83 I CID FAULT - CHECK CID AT SENSOR
Key off. Yes ~ CID circuit is open

between the camshaft
Connect the LED test lamp between (+) J21 (CID sensor and DIS
CS) and (-) J60 (BAT -). module. CHECK
Does LED test lamp blink continuously when connectors or SERVICE
engine Is cranked' or started? harness. RERUN Quick
Test.
.
No ~ GO to 1841.
84 I CID FAULT-CHECK CAMSHAFT" SENSOR

VANE
Key off. Yes ~ REPLACE camshaft

sensor. RERUN Quick
Remove camshaft sensor. Test.
Does cams~aft vane move through sensor air
gap when engine is cranked? No ~ Refer to Engine Shop
Manual Group.

ALL RIGHTS RESERVED

Continuous Memory Code 18: IDM Failure Or CID 8
TEST STEP RESULT ,~ ACTION TO TAKE
85 IIDM FAULT - CHECK DIS MODULE 10M - -

OUTPUT

Connect diagnostic cable -to breakout box. No ~ GO to IS71.
Connect LED test lamp between (+) J4 (10M) and
(-) J60, (BAT -).
engine is cranked or started?
86 110M FAULT - CHECK 10M CONTINUITY

RERUN Quick Test.
Is resistance between Test Pin 4 (10M) at
EEC-IV vehicle harness connector and J4 (10M) No ~ 10M is open between
less than 5 ohms? DIS module and
processor. SERVICE
harness and
connectors. RERUN
Quick Test.
B7 IIDM FAULT -ISOLATE EEC-IV PROCESSOR
Key off. Yes ~ REP.LACE processor.

RERUN Quick Test.
Disconnect EECIV processor.
OoesLED test lamp blink continuously whe~
engine is cranked? No ~ GO to Issi.
B8 IIDM FAULT - CHECK FOR SHORT
Key off.- Yes ~ 10M is shorted to. BAT

or ground between DIS
Disconnect HEGO sensor. module and processor.
Disconnect diagnostic cable connector from DIS SERVICE harness and
module (Pins 7-12). connectors. RERUN
Measure resistance between J4 (lDM) and- J60 Quick Test.
(BAT -).
Measure resistance between J4 (IDM) and J2 No ~ REPLACE DIS module.
(IGND D). RERUN Quick Test.
Measure resistance between J4 (IDM) and J5
(VBAT D).
Is each resistance less than 10K?

ALL RIGHTS RESERVED

Continuous Memory Code 18: IDM Failure Or CID B
B9 IIDM FAULT - CHECK FOR SHORT TO VBAT
Is resistance between J4 (10M) and J57 (BAT+) Yes ~ IDM is shorted to

less than 10K ohms? ground between DIS
SERVICE harness and
connectors. RERUN
Quick Test.

RERUN Quick Test.

ALL RIGHTS RESERVED

Continuous Memory Code: 19
Test
c
CID to EEC Failure
C1 I CHECK CID EEC AT CAMSHAFT SENSOR

No ~ GO to Ical.
Connect LED test lamp between (+)J22 #
(CID EEC) and (-) J60 (BAT -).

Does LED Test Lamp blink continuously during
crank or when engine is running?
C2 I CHECK CID TO EEC CONTINUITY

, RERUN Quick Test.
Disconnect EEC-IV processor.'
Is resistance between J22 (CID EEC) and Test No ~ CID is open between
Pin 24 (CID) at EECIV vehicle harness DIS module and
connector less than 5 ohms? processor. SERVICE
harness and
connectors. RERUN
Quick Test.
C3 I CHECK CID DIS AT CAMSHAFT SENSOR
Connect LED test lamp between (+) J21 Yes ~ CID is open between
(CID CS) and (-) J60 (BAT - ). J21 (CIG CS) and J22
(C/P EEC). REPLACE'
Does LED test lamp blink continuously ~uring camshaft sensor.
crank or when engine Is running? RERUN Quick Test.
,
No ~ GO to IC41.
C4 I CHECK CAMSHAFT SENSOR VBAT c
Connect LED test lamp between (+) J41 Yes ~ GO to lcsl.

(VBAT CS) and (-) J60 (BAT -).
Keyon. No ~ VBAT fault at sensor.
SERVICE connectors
Is LED test lamp on? and harness. RERUN
Quick Test.

ALL RIGHTS RESERVED
3.0L SEFI SHO and 3.8L SEFI SC DIS. Pinpoint

Test
c
CID to EEC Failure
C5 I CHE:CK CAMSHAFT SENSOR IGNITION

GROUND
Key off. Yes ~ GO to IC6\.

Is resistance between J42 (IGND CS) and J60
(BAT -) less than 5 ohms? No ~ IGND open at se.nsor.
SERVICE connectors
and harness. RERUN
Quick Test.
,
C6 I ISOLATE DIS MODULE

Disconnect diagnostic cable connector from DIS RERUN Quick Test.
module connector (Pins 1-6).
Connect the LED test lamp between (+) J22 (CID No ~ GO to IC71.
EEC) and (-) J6D (BAT -).
C7 I ISOLATE EEC-IV PROCESSOR

Leave LED test lamp connected between (+) J22 RERUN Quick Test.
(CID EEC) and (-) J6D (BAT -).
Disconnect EEC-IV processor. No ~ GO to Icsl.
C8 I CHECK CID EEC FOR SHORT TO GROUND
Key o~f. Yes ~ CID EEC is shorted to

Disconnect HEGO sensor. VBAT or ground
between sensor and
Disconnect LED test lamp. EEC-IV processor.
Disconnect diagnostic cable connector from SERVICE connectors
camshaft sensor. and harness. RERUN
Quick Test.
module (Pins 7-12).
Measure resistance between J2 (IGND D) and J22 No ~ GO to ICgl.
(CID EEC).
Measure resistance between J6D .(BAT -) and
J22 (CID EEC).
Measure resistance between J22 (CID EEC) and
J5 (VBAT D).
Is each resistance less than 10K ohms?

ALL RIGHTS RESERVED
3.0L SEFI SHO and 3.8L -SEFI SC DIS Pinpoint

Test
c
CID to EEC Failure
C9 I CHECK CID CS FOR SHORT TO GROUND
Key off. Yes ~ CI D CS is shorted to

VBAT or ground
Measure resistance between J2 (IGND D) and between sensor and
J21 (CID CS). DIS module. SERVICE
Measure resistance between J60 (BAT -) and J21 connectors and
(CID CS).
Test.
Measure resistance between J21 (CID CS) and
J5 (VBAT D). No ~ GO to IC101.
C10 I CHECK CID VANE
Remove camshaft sensor. Yes ~ GO to IC111.

Does vane move t~rough air gap when engine
is cranked? No ~ Refer to Engine Shop
Manual Group.
C11 I CHECK FOR CAMSHAFT SENSOR DAMAGE
Inspect camshaft sensor and vane for damage or Yes ~ REPLACE camshaft
corrosion. sensor. RERUN Quick
Test.
Is unit OK?
No ~ REPLACE or SERVICE
as required. RERUN
Quick Test.
I

ALL RIGHTS RESERVED

Continuous Memo~ Codes 45, 46 or 48: D
Coil 1, 2 or 3 Failure Test
01 I CHECK DIS MODULE DRIVERS
Key off. Yes ~ REMOiE jrmper wire.

GO to 02 .
Disconnect diagnostic cable connector to DIS
Module vehicle harness connector (Pins 7-12). No ~ REMOVE jumper wire.
REPLACE DIS module.
Connect a jumper between J2 (IGND D) and J55 RERUN Quick Test.
(IGND PS).
For Code 45:
- Connect LED test lamp between (-) J3 (C1 D)
and (+) J57 (BAT +).
For Code 46:
(C2D) and (+) J57 (BAT +).
For Code 48:
- Connect LED test lamp between (-) J6 (C3D)
and (+) J57 (BAT+).
engine is cranked?
02 I CHECK HARNESS TO IGNITION COIL

Reconnect diagnostic cable connector to DIS
Module vehicle harness connector (Pins 7-12). No ~ GO to 1041.
Disconnect diagnostic cable connector from coil
pack.
'For 3.0L SEFI SHO:
- Code 45: Connect LED test lamp between (-)
J12 (C1C) and (+) J57 (BAT+).
J14 (C2C) and (+) J57 (BAT+).
J13 (C3C) and (+) J57 (BAT+).
For 3.8L SEFI SC:
J14 (C1C) and (+) J57 (BAT+).
J12 (C2C) and (+) J57 (BAT+).
J13 (C3C) and (+) J57 (BAT+).

ALL RIGHTS RESERVED
3.0L SEFI SHO and 3.8L SEFI SC DIS Pinpoint .,

Continuous Memo~ Codes 45, 46 or 48: D'
D3 J CHECK VBAT AT COIL PACK

. -
Key off. Yes ~ REPLACE coil pack.
RERUN Quick Test.
Reconnect coil pack.
Connect LED test lamp, between (+) J7 No ~ VBAT open at coil
(VBAT C) and (-) J6D (BAT -). pack. SERVICE
harness and
Key on. connectors. RERUN
Is LED test lamp on? Quick Test.
.-
D4 1
CHECK DIS MODULE TO COIL PACK
CONTINUITY

For 3.0L SEFI SHO:
- Code 45: Measure resistance between J3 DIS module and coil
(C1 D) and J12 (C1 C). pack. SERVICE
connectors and
- Code 46: Measure resistance between J18
(C2D) and J14 (C2C).
Test.
' .
For 3.8L SEFI SC:
(C1 D) and J14 (C1 C).
,
Is each resistance less than 5.0 ohms?

ALL RIGHTS RESERVED

Continuous Memo~ Codes 45, 46 or 48: D
05 I CHECK FOR SHORT TO GROUND IN

HARNESS

VBAT between DIS
Disconnect HEGO sensor. module and coil pack.
Disconnect diagnostic cable connector from DIS SERVICE connectors
module (Pins 7-12). and harness. RERUN
Quick Test.
Disconnect diagnostic cable connector from coil
pack. No ~ Circuit is shorted to
For Code 45: ground between DIS
module and coil pack.
- Measure resistance between J3 (C1 D) and J5 SERVICE connectors
(VBAT D). and harness. RERUN
For Code 46: Quick Test.
- Measure resistance between J18 (C2D) and J5

(VBAT D).
For Code 48:
- Measure resistance between J6 (C3D) and J5
(VBAT D).

ALL RIGHTS RESERVED

3.8L SEFI SC DIS E
No Codes - Engine Hard to Start Test
E1 ICHECK CID TO DIS MODULE AT CAMSHAFT

SENSOR
Key off. Yes ~ GO to IE21.

No ~ REPLACE camshaft
Connect diagnostic cable to breakout box. sensor. RERUN Quick
Use 3.0L/3.8L overlay. Test.
Connect LED test lamp between (+) J21

(CID CS) and (-) J60 (BAT -).
crank or engine runni.ng?
E2 I CHECK CID CS AT DIS MODULE

RERUN Quick Test.
Connect LED test lamp betw~en (+) J51 (CID D)
and (~) J60 (BAT - ).
Does LED test lamp blink continuously during camshaft sensor and
crank or engine running? DIS module. SERVICE
connectors and
Test.
..
,

ALL RIGHTS RESERVED

Engine Running Code 18 or Continuous Memory Code 49: F
Spout Open, Short to VBAT Or Short to Ground Test
F1 CHECK FOR SPOUT SIGNAL AT DIS MODULE

RERUN Quick Test.
.Install diagnostic cabie.
Connect diagnostic cable to breakout box. No ~ GO to IF21.
and (-) J60 (BAT - ).
Does LED test. lamp blink continuously when
engine is cranked or when engine is running?
F2 CHECK FOR SPOUT SIGNAL AT

SPOUT IN-LINE CONNECTOR
Key off. Yes ~ GO to IFSI.,

Remove SPOUT in-line connector plug from
SPOUT in-line connector. No ~ GO to IF31.
'. Connect the LED test lamp between (-) J60
(BAT -) and (+) SPOUT in-line connector
(EEC Side).
engine is started?
DIS SIDE ~ EEC SIDE

F3 CHECK SPOUT CIRCUIT CONTINUITY

BETWEEN EEC-IV PROCESSOR AND SPOUT
IN-LINE CONNECTOR

Measure resistance between Test Pin 36 (SPOUT) spout in-line connector
of processor vehicle harness connector and and EEC-IV processor.
SPOUT in-line connector (EEC Side). SERVICE harness and
Is resistance less than 5.0 ohms? connectors. RERUN
Quick Test.
DIS SIDE ~ EEC SIDE

ALL RIGHTS RESERVED

Engine Running Code 18 or Continuous Memorv Code 49: F
Spout Open, Short to VBAT Or Short to Ground Test
F4 CHECK SPOUT CIRCUIT FOR SHORTS TO

VBAT AND GROUND BETWEEN EEC-IV .
PROCESSOR AND SPOUT IN-LINE
CONNECTOR
~ Key off. Yes ~ SPOUT circuit is

.shorted to VBAT or
Disconnect HEGO sensor. ground between
Disconnect EEC-IV processor. . SPOUT in-line
connector and EEC-IV
Measure resistance between J5 (VBAT D) and processor. SERVICE
SPOUT in-line connector (EEC Side). connectors, SERVICE/
. REPLACE harness.
Measure resistance between J60 (BAT -) and RERUN Quick Test.
SPOUT in-line connector (EEC Side).
Is either resistance less than 6K ohms? No ~ GO to IFSI.
DtSSIDE ~ EECSIDE ,
SPOUT INLlNE VEHICLE
F5 CHECK SPOUT CIRCUIT CONTINUITY

BETWEEN DIS MODULE AND SPOUT IN-LINE
CONNECTOR

Measure resistance between J36 (SPOUT) and
SPOUT in-line connector (DIS side). No ~ Circuit is open between
SPOUT in-line
Is resistance less than 5.0 ohms? connector and DIS
module. SERVICE
DIS SIDE ~ EECSIDE connector, SERVICE/
REPLACE harness.
SPOUT INLINE VEHICLE RERUN Quick Test.

ALL RIGHTS RESERVED

Engine Running Code 18 or Continuous Memory Code 49: F
Spout Open, Short to VBAY Or Short to Grouna Test
F6 CHECK SPOUT CIRCUIT FOR SHORTS TO

VBAT AND GROUND BETWEEN DIS MODULE
AND SPOUT IN-LINE CONNECTOR
Key off. Yes ~ SPOUT circuit is

shorted to BAT + or
Disconnect Diagnostic Cable connector from DIS ground between
module (Pins 1-6). SPOUT in-line
Measure resistance between J5 (VBAT D) and connector and DIS
module. SERVICE
SPOUT in-line connector (DIS Side).
connectors, SERVICE/
Measure resistance between J60 (BAT -) and REPLACE harness.
SPOUT in-line connector (DIS Side). RERUN Quick Test.
Is either resistance less than 6K ohms?
DIS SIDE ~ EECSIDE
RERUN Quick Test.
SPOUT INLlNE VEHICLE


ALL RIGHTS RESERVED
Ignition Systems; Timing Procedures .and Diagnosis 13-159
3.0L SEFI SHO and 3.8L SEFI SC DIS PinpoinOt

(Bad Plugs, Wires or Short to Gr~und) Test
PRELIMINARY NOTES
. .
system.
CHECKOUT
Visually inspect the engine compartment to ensure all vacuum hoses and spark plug 'wires
are properly routed and. securely connected.
EQUIPMENT
DIS Adapter Rotunda 007-00044.

ALL RIGHTS RESERVED

Misfire Under Load . G

essential that the calibration of your engine analyzer be maintained. Refer to your
equipment manual. If this is not available, an estimate of the calibration can be made
by connecting the spark tester (D81P-6666-A or equivalent) to a properly operating
ignition system and measuring the firing voltage of the spark tester only. Do not
Include the firing voltage of the rotor-to-cap gap. The spark tester firing voltage
should be approximately 28 KV.


ALL RIGHTS RESERVED

(Bad Plugs, Wires or Short to' Ground) Test
. . . TEST STEP ~
~
RESULT .
ACTION TO TAKE

20
value of ,spark values for a properly
plug firing operating ignition
15- . voltage: 15 KV system.
. or less with
10- evenness of
KV spark plug firing
5-
-
~ voltage: 5 KV
0- ~ ~ '--1, or less
I' I l' ~
5
-
1 3 4 2
CYLINDER A12753-A

20 value of spark cylinders:
- plug firing
15- voltage: greater CHECK ignition coil
. than 15 KV wires for proper
10- with evenness installation in coil.
KV of spark plug
5-,A ~ 'J
_ 0-
-
- I
I&.
IL. I.
r ~
firing voltage: 5
KV qr less.
MEASURE resistance
of ignition wires.
REPLACE if greater
5 than 7,000 ohms per
1 3 4 2 foot.
CYLINDER A12154A
Wide spark plug
gaps - all cylinders
(usually from worn
mileage).

20 spark plug firing some cylinders:
voltage: greater
15_ than 5 KV Wide spark plug gap(s)
. or worn electrode(s).
10- .
KV
5- ~ li
o_~,. II.
r ....
~
5
1 3 4 2
CYLINDER A12752A

ALL RIGHTS RESERVED


20
high spark plug firmly connected.
firing voltage in
15- one or more Disconnected spark
cylinders plug wire(s).
to-
KV Wide spark plug gapes).
~
5
0- ~ - . ..- L
It- Open plug wire(s).
5

1 3 4 2
CYLINDER A12751-A
Consistently low ~ Fouled spark plug(s).

20 spark plug firing
15-
sloping spark gapes).
.. line in one or
10- more cylinders Spark plug wire(s)
KV grounding on engine.
s- Inspect for damage.

0- ~L

I- ,. , ~ ~
5
1 3 4 2
CYLINDER A 12750-A

ALL RIGHTS RESERVED
Ignition Systems,' Timing Procedures and Diagnosis 13-163
3.0L SEFI and Pinpoint

3.8L SEFI SC DIS H
No Codes - Intermittent' Diagnosis Test
H1 I
Talk to owner.
I
. Symptoms.
H2
Review vehicle service history. . Number of previous

repairs and
components replaced.
H3 I
. IH41.
.
Will engine start? Yes GO to
No GO to IA11.
H4 I SHAKE TEST
Engine at idle, Raise hood, Shake wiring harness

and Pull wires at connectors for ignition
components.
Yes . SERVICE wiring
harness or connector.
CHECK DIS mounting
bolts. RERUN Quick
Does engine quit?
.
Test.
No GO to IHSI .
H5 I TEMPERATURE CHECK
. IH91 .
.
Engine at idle, Close hood, AIC ON, Blower on Yes GO to
medium speed. Allow engine to run for 15
minutes.
No GO to IH61.
D'oes engine quit?
H6 I HOT SOAK CHECK
. IH71 .
.
Engine off, hood closed, hot soak for 10 minutes. Yes GO to
No GO to IA11.
H7 I HOT SHAKE CHECK
Engine at idle, raise hood, shake wiring harness

and pull wires at connectors for ignition
components.
RERUN Quick Test.
Does engine qUit?
No . GO to IHal.

ALL RIGHTS RESERVED
3.0L SEFI and Pinpoint

3.8L SEFI SC DIS H
I ROAD
H8 CHECK
. IH91.
.
Road test Yes GO to
Does engine quit?
No Test complete.
I ROAD
H9 SHAKE CHECK
Raise hood, Shake wiring harness, pull wires at

connectors, separate and reconnect connectors for
.
ignition components. RERUN Quick Test.
. Does engine quit?

No GO to IA11.

ALL RIGHTS RESERVED
IGNITION SYSTEM
DIAGNOSTIC
PROCEDURE (EDIS)
4.0L EFI TRUCK

ALL RIGHTS RESERVED
Index: 4.0L EFI Truck EDIS
NOTE: Start all diagnostics with Section 14 (EEe-IV Quick Test) first. The tests in this
Section are dependent on results from tests conducted in Section 14.
Subject Page
Preliminary Checkout, Equipment and Notes 13-167
EDIS Diagnostic. Cable ' : 13-168
4.0L EFI Truck EDIS Module and Pin-Out 13-169
4.0L EFI Truck EDIS Wiring Schematic 13-170
EDIS Schematic and Breakout Box Overlay Acronyms : 13-171
4.0L EFI Truck EDIS System and Component Description 13-172
4.0L EFI Truck EDIS Block Diagram 13-175
4.0L EFI Truck EDIS Waveforms 13-176
4.0L EFI Truck EDIS Component location 13-177
4.0L EFI Truck EDIS Pinpoint Test Diagnostics 13-178

ALL RIGHTS RESERVED
CHECKOUT
Examine all wiring harnesses and connectors for insulation damage, and burned, overheated,
damaged' pins, loose or broken conditions. Check sensor shield connector. Make sure
EDIS Module mounting screw is tight.
Obtain the following test equipment or an equivalent
EDIS Diagnostic Cable (Rotunda 007-00059) (refer to Figure.1).
Spark Tester, Neon bulb type (OTC D89P-6666-A).
Volt/Ohm Meter (Rotunda 014-00407).
Spark Tester, Gap type (Special Service Tool 081 P-6666-A). A spark plug with a broken
Inductive Timing Light (Rotunda 059-00006).
NOTES
volt. Also VBAT readings mean any value that falls within a range of VBAT to 2 volts less
than VBAT.
battery lead or cast iron on the engine. SAT + means the positive battery cable at the
battery.
the plug boot. Very weak or no flashing may be caused by a fouled plug.
circuit and may cause erroneous measurements or improper EDIS/EEC-IV operation. (ie.,
engine stall).

ALL RIGHTS RESERVED
13168 Ignition Systems, Timing Procedures and Diagn0818
EDIS Diagnostic Cable
EDIS
MODULE
1.9L COIL TEE
(NOT USED) 4.6L COIL TEE
(NOT USED)
BAT-
BAT + V""'--- _ BREAKOUT
BOX
OR
MONITOR
BOX
A13593A
Figure 1 4.0L EFI Truck EDIS Hook-Up

ALL RIGHTS RESERVED
4.0L EFI Truck EDIS Module and Pin-Out
A13594-A
Figure 2 4.0L EFI Truck EDIS Module and Pin-Out
Pin Number 4.0L EDIS

1 PIP
2 10M
3 SAW
4 IGN GNO
5 VAS-
6 VAS+
7 VAS Shield
8 .VBAT
9 GNO
10 Coil 1
11 Coil 3
12 Coil 2

ALL RIGHTS RESERVED
....
W
..........
I
o
~
~
t: C::>
Q3
t..)
VR
SENSOR
EDIS
r-
~
MODULE
rn
~
i ... TACHOMETER
10M 4 ....
~
~
- .;
;i F ~ PIP 56 TO
EECIV
...c-f
~
I
I
I
I
SAW 36
PROCESSOR
n
I I I , IGN GND 16 ~
gj L ?"\
Ci5
I
I rn
~
~.
I
IL _
SAW
DISCONNECT
BAT ....o
(I)
g>
;:)-
....~
...
(1)
3
Q)
GND
VEHICLE
....
:s
~ BATTERY
tQ
~
~
;:;
(I) 0"
~
n en
:r
IGNITION
COIL
~
a -
'<
o
CD
3
!It
C
....
P+
n
-I
3"
BAT +
VBAT :i"
ea
-0
~
o
n
CD
c.
c
~
CD
o
I
ALL RIGHTS RESERVED
~
A13611A C.
c
iii"
ea
~
o
o
iii'
EDIS Schematic and Breakout Box Overlay Acronyms
There is a logic to the names on the Schematic and Overlays for the EDIS DIAGNOSTIC
HARNESS that will help you.
EDIS Acronyms
PIP Profile Ignition Pickup (EDIS output signal).
SAW .Spark Angle Word (EEC Spark control signal).
IGND Ignition Ground (Low current ground reference).
VRS- Variable Reluctance Sensor Negative:
VRS+ Variable Reluctance Sensor Positive.
VRS Shield Variable Reluctance Sensor Shield.
BAT+ Battery Positive.
GND or BAT- Battery Negative.
VBAl Ignition Power to component.
C1, C2, C3 Coil Drive (For Coils 1, 2 and 3).
Overlay Designators
that tells you where the measurement is being taken. The key to these letters is:
Suffix "E" is at the EDIS Module.
Suffix "s" is at the sensor.
VBAl C means VBAl at the Coil.
VBAl E means VBAl at the EDIS Module.

ALL RIGHTS RESERVED
4.0L EFI Truck EDIS System and

Component Description
SYSTEM DESCRIPTION
The 4.0L EFI Truck Electronic Distributorless Ignition System (EDIS) consists of a Variable
Reluctance Sensor (VRS), an EDIS Ignition Module, an EEC IV processor and one 6-Tower
Coil Pack.
The Electronic Distributorless Ignition System (EDIS) operates by sending crankshaft position
information from the VR sensor to the EDIS module. The module generates a PIP signal and
sends it to the EEC-IV processor. The processor responds with a Spark Angle Word (SAW)
signal containing advance or retard timing information back to the EDIS module. The module
processes the VRS and SAW signals and decides which coils to fire. In addition; the module
generates an Ignition Diagnostic Monitor (10M) signal to the processor which is used to
indicate a failure mode and also provide a tach output signal.
COMPONENT DESCRIPTION
VR Sensor
The VR sensor is a passive electromagnetic device which senses movement of a 36 minus

one-tooth wheel located behind the crankshaft pulley. An A/C voltage signal is generated
which increases with engine rpm and provides basic spark timing information to the EDIS
module.
VARIABLE REWCTANCE
SENSOR (VRS) A13596-A

ALL RIGHTS RESERVED

EDIS Module
The EDIS module is a microprocessor based device with coil drivers which make decisions
about spark timing and coil firing. The module turns the coils on and off at the correct time
and in the proper sequence based on information from the VR sensor and a pulse width
modulated signal (SAW) generated from the EEC..IV processor. The module receives VRS and
SAW signals and produces PIP and 10M output signals which are sent to the EEC-IV
processor.
A 13594-A
EECIV Processor
The EEC-IV processor receives IGN GNO and PIP signals from the EOIS module then
generates a SAW output signal based upon fuel, air and other sensor information. An 10M
signal is received from the EOIS module to determine if a failure mode should be recorded.
A13597A

ALL RIGHTS RESERVED

Coil Pack
The coil receives active low signals from the EDIS module and fires two spark plugs at once,
one is for the cylinder which is to be fired (on compression stroke) and the other goes to the
mating cylinder which is on the exhaust stroke. The next time the coil is fired the situation is
reversed. The next pair of spark plugs will fire according to the engine firing order etc.
COIL PACK
A13598A

ALL RIGHTS RESERVED
4.0L EFI Truck EDIS

Block Diagram
~VBAT
CRANKSHAFT WHEEL
8
VAS ~
VAS-
VAS SHIELD
10M
2 ......- - -...- - - - : . (TACH)
EOIS-6 SAW
~ VBAT
~ODULE
5 PIP
IGNO
4
COIL 1 7
'0
COIL 2
12 11 9
ENGINE
BLOCK COIL 3
GND
ENGINE
BLOCK
+VPWA
37 57
EECIV
PROCESSOR
+VBAT ~VPWR 16)--H---'

561E-j~-'"
36~~---I
EEC
PWA
RELAY
4 . . .- - - - - - '
BATTEAY
NEGATIVE
POST
A13599-A
Figure 4 4.0L EFI Truck EDIS

ALL RIGHTS RESERVED
4.0L EFI Truck EDIS Waveforms
Timing Diagram
VRS
10 BTDC
I
PIP
1_______
20 ATDC
I
__n no-.-_
20 BTDC
SAW --.-11 ~1 n
I J1
COIL
CURRENT
______11 COIL 1 COIL 2 J1 COIL 3
I
IDMITACH
_ _n n ------"n _
180 BTDC
A13600A
Figure 5 4.0L EFI Truck EDIS Waveforms

ALL RIGHTS RESERVED
4.0L EFI Truck EDIS Component Location
VARIABLE RELUCTANCE SENSOR LOCATION
36-1 TOOTH WHEEL
PULLEY AND
DAMPER ASSY
SENSOR ASSY-
CRANKSHAFT TIMING A13603A
EDIS MODULE LOCATION
RangerIBronco II Aerostar
RIGHT INNER
FENDER APRON
RIGHT INNER
FENDER APRON
;[)-~
--- -
1~
RADIATOR SUPPORT
FRONT OF
VEHICLE
Figure 6 EDIS Component Locations

ALL RIGHTS RESERVED
4.0L EFI Truck EDIS Pinpoint

Index
No Start with:
No service code Go to A
Continuous Memory Code 14 Go to A
Continuous Memory Code 18 Go to A12
Key On Engine Off Code 16 Go to A14
Engine Running with:
- Key On Engine Off Code 16 or Continuous Memory Code 18 and/or Go to B

Check Engine Light On
- Continuous Memory Code 45 and/or "Check Engine" Light On Go to C
- Engine Running Code 18 and/or Lack of Power Go to 0
- Engine Miss Drive Complaint (and no service code) Go to 3.0L/3.8L G
- Engine Intermittent Drive Complaint (and no service code) Go to 3.0L/3.8L H
Using the LED Test Lamp
You may use the LED test lamp (see circuit below) to supplement the DVOM. It will save time
when checking the PIP and coil circuits.
TIP OR BANANA JACKS TO

SUIT EEC BREAKOUT BOX.
LED 1
R1 1-- - - - I
:t-----~
R1 RADIO SHACK 271-019470n.
R2 RADIO SHACK 271-019 4700.
A13605-A
Use the LED test lamp to check power, PIP and Coil circuits.
The LED test lamp is "on" if LED 1 shows green or red.
Using a DVOM
If using a DVOM to check the PIP signal, the engine must be turned very slowly (bumped)
with the starter. This is a digital signal and should switch from ground (0 VDC to .5 VDC) to
BAT + (8 VDC to 14 VDC) or BAT + to ground. When using the DVOM correct test lead
polarity must be used. The red lead is + (positive) and black lead is - (negative).

ALL RIGHTS RESERVED
14.OL. EFI Truck EDIS Pinpoint

A
No Start . Test
TEST STEP RESULT. ~. ACTION TO TAKE
A1 I PERFORM EECIV QUICK TEST
Refer to Section 14 and perform EECIV Quick Yes ~ GO to IA21.

Test.
Has Quick Test been performed? No ~ GO to Section 14 first
and perform Quick
Test.

;
Using a Neon Bulb Spark Tester (OTC 0 89P Yes ~ GO to IA31.

6666-A), check for spark at all spark plug wires
while cranking. No ~ GO to IA101.
revolution)?
A3 I CHECK PIP AT EDIS. MODULE

o.
Key off. Yes ~ GO to.IA41.
Install EDIS diagnostic cable to breakout box.
Use EDIS 6 overlay.
No ~ GO to IA71.
Connect LED test lamp between J43 (PIP E) and
J7 (GND).
Does the LED test lamp blink continuously
during crank?
A4 I CHECK PIP CONTINUITY TO EEC
~ GO to IASJ.
.
Key off. Yes
Disconnect the EEC processor.
No SERVICE open circuit.
Is the resistance between J43 (PIP E) and. Pin RECONNECT the EEC
56 (PIP) of the EEC connector less than S processor and RERL!N
ohms? Quick Test.
I CHECK
AS IGND AT EDIS
.
.
Key off. Yes GO to IAsl .
Is the resistance between J47 (IGND E) and J7
(BAT -) less than 5 ohms? No REPLACE EDIS module
and RERUN Quick
Test.

ALL RIGHTS RESERVED
14.OL EFI Truck EDIS Pinpoint

A
No Start Test
A6 I CHECK IGND CONTINUITY TO EEC
Key off. Yes ~ REPLACE EDIS

module. RUN Quick
Is the resistance between J47 (IGND E) and Test.
Pin 16 (IGN GND) of the EEC connector less
than 5 ohms?
RECONNECT EEC and
RERUN Quick Test.
A7 I CHECK PIP AT EDIS MODULE/ISOLATE EEC
Key off. Yes ~ REPLACE EEC

processor. RERUN
Disconnect the EEC processor. Quick Test.
Crank the engine.
Does the LED test lamp blink continuously No ~ GO to IASI.
during crank?
A8 I CHECK PIP CIRCUIT FOR SHORT TO GROUND
Key off. Yes ~ PIP is shorted to

ground in harness.
Disconnect the EDIS module from the EDIS CHECK connectors,
diagnostic cable. SERVICE or REPLACE
Disconnect the HEGO sensor. harness. RERUN Quick
Test.
Is the resistance between J43 (PIP E) and J7
(BAT -) less than 5 ohms?
No ~ GO to IA91.
A9 I CHECK PIP CIRCUIT FOR SHORT TO POWER
Is the resistance between J43 (PIP E) and J51 Yes ~ PIP is shorted to
(VBAT E) less than 5 ohms? power in harness.
CHECK connectors,
SERVICE or REPLACE
harness. RUN Quick
Test.
No ~ REPLACE EDIS
module. RERUN Quick
Test.

ALL RIGHTS RESERVED
Ignition, Systems, Timing Procedures and Diagnosis 13-181
1400L EFI Truck EDIS Pinpoint'

A
No Start Test
A10 I DETERMINE MISSING SPARK PATTERN
Is spark missing from BOTH cylinder 1 and 5 Yes ~ GO to IA121.

plug wires? .
or No ~ GO to IA111.
Is spark missing from BOTH cylinder 2 and 6
plug wires?
or
Is spark missing from BOTH cylinder 3 and 4
plug wires?
A 11 I CHECK PLUGS AND WIRES
Check spark plug wires. for insulation damage, Yes ~ REINSTALL p~and
looseness, shorting or other damage. wires. GO to A12 .
carbon deposits and proper plug gap. No ~ SERVICE or REPLACE
Are spark plugs and wires OK? damaged component.
RERUN Quick Test.
A 12 I CHECK VBAT C AT COIL

Use EDIS 6 overlay. No ~ SERVICE open circuit.
RECONNECT the EEC
Connect the LED test lamp between J5 (VBAT C) processor and RERUN
and ~7 (BAT-). Quick Test.
Key On.
Is the LED test lamp on and bright?
A13 I CHECK COIL FOR FAILURE
. Connect LED test lamp between J7 (BAT-) to Yes ~ GO to IA141 .

each coil - J3, J6 and J10, one at a time.
Key on. No ~ REPLACE Coil pack.
Is the LED test lamp on and bright? RERUN Quick Test.
A14 I CHECK GND CONTINUITY TO EDIS MODULE

Is, the resistance between J27 (GND E) and J7
(BAT-) less than,5 ohms? No ~ SERVICE open circuit.
RECONNECT EEC and
RERUN Quick Test.

ALL RIGHTS RESERVED
14.OL EFI Truck EDIS Pinpoint

A
No Start Test
A15 I CHECK GND IN EDIS MODULE

Is the resistance between J27 (GND E) and
J47 (IGND E) less than 5 ohms? No ~ REPLACE EDIS
module. RERUN Quick
Test.
A16 I CHECK VBAT E AT EDIS MODULE
Connect the LED test lamp between J51 (VBAT Yes ~ GO to IA171.
E) and J7 (BAT-).
Keyon. No ~ SERVICE open circuit.
Is the LED test lamp on and bright? RECONNECT the EEC
processor and RERUN
Quick Test.
A17 I CHECK VRS AMPLITUDE AT EDIS MODULE
Is the A/C voltage between J35 (VRS+ E) and Yes ~ GO to IA1SI.

J48 (VRS- E) more than 1 volt when the
engine is cranked?
No ~ GO to IA191.
A18 I CHECK VRS BIAS AT EDIS MODULE
Key on. Yes ~ REPLACE EDIS

Is the DC voltage between J35 (VRS+ E) and module. RERUN Quick
J27 (GND E) between 1.0 and 2.0 volts? Test.
No ~ GO to IA2SI.
A19 I CHECK VRS CRANKING VOLTAGE AT EDIS
Key off. Yes ~ REPLACE EDIS '

Disconnect the EDIS module from the EDIS module. RERUN Quick
diagnostic cable. Test.
Is the A/C voltage more than 1 volt when the
engine is cranked? No ~ GO to IA201.
A20 I CHECK VRS CRANKING VOLTAGE AT
SENSOR

Disconnect the VRS engine harness from the
EDIS diagnostic cable. No ~ GO to IA211.
Is the 'A/C voltage between J32 (VRS S) and
J31 (VRS+ S) more' than.1 volt when the
engine is cranked?

ALL RIGHTS RESERVED
!400L EFI TIU.ck EDIS, Pinpoint

A
No Start Test
A21 ICHECK VR SENSOR AND CRANKSHAFT

WHEEL
Check the crankshaft data wheel for damage. Yes ~ REPLACE VR sensor.
RERUN Quick Test.
Check the air gap.
Is the air gap correct and is the crankshaft No ~ REPAIR or REPLACE
data wheel OK? bad parts. SET air gap.
A22 I CHECK VRS+ CIRCUIT FOR OPEN

Reconnect the EDIS diagnostic cable.
No ~ SERVICE open circuit
Is the resistance between J35 (VRS+ E) and in VRS+ harness.
J31 (VRS+ S) less than 5 ohms? RERUN Quick Test.
A23 I CHECK VRS- CIRCUIT FOR OPEN

Is the resistance between J32 (VRS- S) and
J48 (VRS - E) less than 5 ohms? No ~ SERVICE open circuit
in VRS- harness.
RERUN Quick Test.
A241 CHECK VRS- CIRCUIT FOR SHORT TO

POWER
Key off. Yes ~ GO to IA2SI.

\
Disconnect the HEGO sensor.
No ~ SERVICE short circuit
Is the resistance between J48 (VRS- E) and in VRS- harness.
J51 (VBAT E) greater than 10K ohms? RERUN Quick Test.
A2S1 CHECK VRS- CIRCUIT FOR SHORT TO

GROUND
Is the resistance between J48 (VRS- E) and J7 Yes ~ GO to IA261.

(BAT-) greater than 10K ohms?
in VRS- harness.
" RERUN Quick Test.

ALL RIGHTS RESERVED
1400L EFI Truck EDIS Pinpoint

A
No Start Test
TEST STEP
A261 CHECK VRS+ CIRCUIT FOR SHORT TO

RESULT . ACTION TO TAKE
GROUND
.
.
Is the resistance between J35 (VRS+ E) and Yes GO to IA271 .
J7 (BAT-) greater than 10K ohms?
No SERVICE short circuit
in VRS+ harness.
RERUN Quick Test.

POWER
Is the resistance between J35 (VRS+ E) and

J51 (VBAT E) greater than 10K ohms?
Yes . VRS+ is shorted to
VRS-. SERVICE short
in harness. RERUN
.
Quick Test.

in VRS+ harness.
RERUN Quick Test.
A28 I CHECK
Key off.
VRS BIAS AT EDIS MODULE
Yes . REPLACE VR sensor.
.
Disconnect the VR sensor from the EDIS RERUN Quick Test.
diagnostic cable.
Keyon. No GO to IA291.
Is the DC yoltage between J35 (VRS+ E) and
J7 (BAT-) between 1.0 and 2.0 YO Its?

POWER
.
.
Key off. Yes GO to IA301.
Disconnect the EDIS module from the EDIS
diagnostic cable. No VRS+ is shorted to
Disconnect the HEGO sensor. power in harness.
Is the resistance between J35 (VRS+ E) and CHECK connectors,
J51 (VBAT E) greater than 10K ohms? SERVICE or REPLACE
Test.
A30 I CHECK VRS+ CIRCUIT FOR SHORT TO

GROUND
Is the resistance between J35 (VRS+ E) and .

.
Yes GO to IA311.
J7 (BAT-) greater than 10K ohms?
in VRS+ harness.
RERUN Quick Test.

ALL RIGHTS RESERVED
1400L EFI Truck EDIS Pinpoint

A
No Start Test
~
TESTSTEP RESULT ~ ACTION TO TAKE
A31 I
CHECK VRS - CIRCUIT FOR SHORT TO
POWER
Is the resistance between J48 (VRS - E) and Yes ~ GO to IA321.

J51 (VBAT E) greater than 10K ohms?
in VRS - harness.
RERUN Quick Test.
A321 CHECK VRS - CIRCUIT FOR SHORT TO

GROUND
Is the resistance between J48 (VRS- E) and Yes ~ SERVICE short circuit
J7 (BAT -) less than 5 ohms? in VRS - harness.
RERUN Quick Test.
No ~ REPLACE ED!S
module. RERUN Quick
Test.

ALL RIGHTS RESERVED
13-186 Ignition Systems, Timing Proced~res and Diagnosis

KOEO Code 16, Continuous MemolJ1 Code 18 and/or B
"Check Engine" Light On: IDM Failure Test
B1 I CHECK 10M CONTINUITY TO EEC
Key off. Yes ~ GO to IB21.

No ~ SERVICE open in 10M
Use EDIS 6 overlay. circuit. RERUN Quick
Test.
Is the resistance between J41 (10M E) and Pin
4 (10M) of the EEC connector less than 5
ohms?
B2 I CHECK 10M CIRCUIT FOR SHORT TO

GROUND
Key off. Yes ~ GO to IB31.

Disconnect the EDIS module from the EDIS
diagnostic cable. No ~ IDM is shorted to
ground in harness.
Disconnect the HEGO sensor. CHECK connectors,
SERVICE or REPLACE
Is the resistance between J41 (10M E) and J7
(BAT-) greater than 10K ohms? Test.
B3 I CHECK IDM CIRCUIT FOR SHORT TO POWER
Is the resistance between J41 (10M E) and J51 Yes ~ REPLACE EDIS
(VBAT E) greater than 10K ohms? module. RECONNECT
EEC processor.
RERUN Quick Test. If
fault persists,
REPLACE EEC
processor and RERUN
Quick Test.
No ~ 10M is shorted to
power in harness.
CHECK connectors,
SERVICE or REPLACE
Test.

ALL RIGHTS RESERVED
4.0L EFI TRUCK EDIS Pinpoint

Continuous Memory Code 45 and/or
Test
c
"Check Engine" Light On: Coil Failure
C1 I CHECK FOR COIL SIGNALS AT EDIS

Use the EDIS-6 overlay. No ~ GO to IC21.
Key on.
Connect LED test lamp from J51 (VBAT E) to
each coil - J53, J54 and J55, one at a time.
Does the lamp turn on brightly for each coil?
C2 I CHECK EDIS COIL AT CRANK
Crank engine. Yes ~ GO to Ical.

Does lamp blink at each coil during crank?
No ~ GO to IC41.
C3 I CHECK 'COIL CONTINUITY TO EDIS MODULE

Disconnect EDIS module from the EDIS diagnostic RERUN Quick Test.
cable.
Disconnect the coil pack from the EDIS diagnqstic No ~ SE~VICE open circuit
cable. in coil harness. RERUN
Quick Test.
Is the resistance between J3 and J53, J6 and
J55, J 10 and J54 less than 5 ohms?
C4 I CHECK COIL FOR SHORT TO POWER

Disconnect the coil pack from the EDIS diagnostic RERUN Quick Test.
cable.
Crank the engine. No ~ GO to Icsl.
Does lamp blink at any coli during crank?
C5 ICHECK COIL CIRCUITS FOR SHORT TO

POWER .
Key off. Yes ~ REPLACE EDIS

module. RERUN Quick
HEGO disconnected.
Test.
Disconnect EDIS module from EDIS diagnostic
cable.
No ~ SERVICE short to
Is the resistance between J51 (VBAT E) and power in coil harness
each coil J3, J6 and J 10 greater than 10K RERUN Quick Test.
ohms?

ALL RIGHTS RESERVED
4.0L EFI TRUCK EDIS Pinpoint

Continuous Memory Code 45 and/or
Test
c
"Check Engine" Light On: Coil Failure
C6 I CHECK COIL FOR SHORT TO GROUND

Disconnect the coil pack from the EDIS diagnostic
cable. No ~ REPLACE coil pack.
RERUN Quick Test.
Key on.
Connect LED test lamp from J7 (BAT-) to each
coil - J53, J54 and J55, one at a time.
Does the lamp turn on for each coil?
C7 I CHECK COIL CIRCUITS FOR SHORT TO

GROUND
Key off. Yes ~ SERVICE short circuit

in coil harness. RERUN
Disconnect the EDIS module from the EDIS Quick Test.
diagnostic cable.
Key on. No ~ REPLACE EDIS
module. RERUN Quick
Connect LED test lamp from J7 (BAT-) to each
Test.
coil - J53, J54 and J55, one at a time.
Does the lamp turn on for each coli?

ALL RIGHTS RESERVED
Ignition Systems, Timing Pr.ocedures and Diagnosis 13-189

D
Engine Running Code 18: SAW Failure Test
01 I CHECK FOR SPARK AT WIRES
Engine on. Yes ~ GO to 1021.

Using a -Neon Bulb Spark Tester (OTC D 89P-
6666-A),' check for spark at all spark plug wires. No ~ GO to 1061.
revolution)?
02 I CHECK TIMING WITH TIMING LIGHT
Install timing light. : Yes ~ REFER to engine

diagnostics in Shop
Start engine and warm to normal engine Manual.
temperature.
Transmission out of gear. No ~ GO to J031.
Is the spark angle greater than 19 degrees
BTOC?
03 I CHECK SAW CONTINUITY TO EEC

..
Install EDIS diagnostic cable but do not connect
the EDIS module or coil pack to the cable. No ~ SERVICE open in SAW
circuit. RECONNECT
Connect the cable to the breakout box. the EEC processor and
RERUN Quick Test.
Use the EDIS 6 overlay.
Is the resistance between J45 (SAW E) and
Pin 36 (SAW) of the EEC connector less than
5 ohms?
04 ICHECK SAW CIRCUIT FOR SHORT TO

GROUND

HEGO disconnected.
Is the resistance between J45 (SAW E) and J7
No ~ SAW is shorted to
ground in harness.
(BAT -) greater than 10K ohms? CHECK connectors,
SERVICE or REPLACE
Test.

ALL RIGHTS RESERVED
13-190 Ignition Systems, Timing Procedures andOiagnosis

D
Engine Running Code 18: SAW Failure Test
05 I CHECK SAW CIRCUIT FOR SHORT-TO-POWER
Is the resistance between J45 (SAW E) and Yes ~ REPLACE EDIS

J51 (VBAT E) greater than 10K ohms? module. RECONNECT
EEC processor.
RERUN Quick Test. If
fault persists,
REPLACE EEC
processor and RERUN
Quick Test.
No ~ SAW is shorted to
ground in harness.
CHECK connectors,
SERVICE or REPLACE
Test.
D6 I CHECK PLUGS AND WIRES
Check spark plug wires for insulation damage, Yes ~ REPLACE coil pack.
looseness, shorting or other damage.
carbon deposits and proper plug gap.
No ~ SERVICE or REPLACE
damaged component.
Are spark plugs and wires OK? RERUN Quick Test.

ALL RIGHTS RESERVED
HOW TO USE QUICK TEST
. SPECIAL NOTES:
START with Section 14, EEC-IV Quick Test Procedures and Appendix when directed here by
Section 2, Diagnostic Routines.
Sections 15 and 16, Engine Supplement Sections for Passenger Car and Truck, contain
EEC-IV system electrical schematics, circuit numbers, wire colors, pin usage applications and
Quick Test code definitions.
Section 17 contains the EEC-IV Pinpoint Tests.
Refer to Sections 1 and 3 to identify the emission components on your vehicle.
An open is defined as any resistance reading greater than 5 ohms unless otherwise
specified.
A short is defined as any resistance reading less than 10,000 ohms to ground, unless
otherwise specified.
Quick Test results are dependent on the proper operation of base engine components. It
may be necessary to correct any defects in these areas before the EEC-IV system will pass
Quick Test. (Refer to Section 2, Diagnostic Routines, for service).
When more than one service code is received, always start service with the first code
received.
Before using a Pinpoint Test always read the information on the cover page(s) (Le. Notes,
Remember and Pinpoint Test Schematic).
When using a Pinpoint Test, follow each step in order. After completion, verify that all
components are properly reconnected and rerun Quick Test or verify that the drive complaint
has been eliminated.
"RERUN Quick Test" means return to Section 14 and run Quick Test Steps 1.0 thru 9.0.

ALL RIGHTS RESERVED
HOW TO USE QUICK TEST
I
The standard Ford color abbreviations are:
BK Black N Natural
BL Blue o Orange
BR Brown PK Pink
DB Dark Blue P Purple
DG Dark Green R Red
GY Gray T Tan
GR Green W White
LB Light Blue Y Yellow
LG Light Green
Where two colors are shown for a wire, the first color is the basic color of the wire. The
second color is the stripe marking.
For example:
BRIO is a brown wire with an orange stripe.
OPTIONAL USE OF THE EEC-IV MONITOR BOX:
An EEC-IV Monitor Box can be used as a substitute for the EEC-IV Breakout Box during
Pinpoint Testing. The EEC-IV Breakout Box and Monitor Box are pin for pin compatible when
referencing the 60 pin connector. For Monitor Box operation, refer to Section 18.
Turn the key off and isolate both ends of a circuit whenever checking for shorts or
continuity.
Disconnect solenoids and switches from the harness before measuring for continuity,
resistance or energizing by way of a 12 volt source.
When disconnecting connectors, inspect for damaged or pushed-out pins, corrosion, loose
wires, etc. Service as necessary.
IDON'T I
Go to the Pinpoint Test Section unless directed by the Quick Test procedures. (Not following
Quick Test procedures may produce incorrect results and replacement of non-defective
components.)
Replace any parts unless directed by a test procedure.
Measure voltage or resistance directly at the processor connector.

ALL RIGHTS RESERVED
SECTION 14
EEC-IV Quick Test

Procedures and Appendix
Contents
QUICK TEST
Quick Test: Special Notes 14-1
Quick Test 14-2
Step 1.0 Visual Check 14-2
Step 2.0 Vehicle Preparation and Equipment Hookup 14-2
Step 3.0 Perform Key On Engine Off Self-Test 14-3
Step 3.1 Check for Continuous Memory
Service Codes 45, 46 and 48 14-4
Step 4.0 Computed Timing Check 14-4
Step 5.0 Perform Engine Running Self-Test 14-5
Step 6.0 Key On Engine Off Code Charts 14-6
Step 7.0 Engine Running Code Charts 14-8
Step 8.0 Continuous Memory Code Charts 14-11
Step 9.0 Diagnosis By Symptom 14-14
APPENDIX
Self-Test
Visual Check 14-20
Vehicle Preparation and Equipment Hookup 14-21
Key On Engine Off Self-Test 14-23
Engine Running Self-Test 14-24
Continuous Memory Self-Test 14-25
(Continued)

ALL RIGHTS RESERVED
SECTION 14
EEC-IV Quick Test

Procedures and Appendix
Self-Test Description
Contents : 14-26
Code Output Format 14-28
Continuous Self-Test 14-29
Self-Test With STAR Tester 14-30
Self-Test With Analog Voltmeter 14-33
Self-Test With "Check Engine" or "SERVICE ENGINE SOON"
Light (Mil) 14-34
Self-Test With Message Center (Continental Only) 14-35
Self-Test With Overdrive Cancel/Transmission
Malfunction Indicator Light - OCll/TMll 14-36
Diagnostic Aids
Continuous Monitor Test (Wiggle Test) 14-37
How To Clear Continuous Memory Codes 14-38
How To Clear Keep Alive Memory (KAM) 14-38
Output State Check 14-38
Cylinder Balance Test 14-39
Failure Mode Effects Management (FMEM) 14-41
"CHECK ENGINE" or "SERVICE ENGINE SOON"
Light (Malfunction Indicator Light) 14-42
"Check Engine" /"Check DCl" Message
(Data Communications Link) 14-44
Test Equipment..................................................................... 14-45

ALL RIGHTS RESERVED
EECIV Quick Test Procedures and Appendix 141
QUICK TEST: Special Notes
This diagnostic procedure is used ONLY on vehicles equipped with fourth generation
Electronic Engine Controls (EEC-IV).
The QUICK TEST procedure should be used ONLY when the Diagnostic Routines, Section 2
directs you here.
The Key On Engine Off and Engine Running Self-Tests detect faults that are present at the
time .of testing. Intermittent faults that have occurred in the last * 40 warm-up cycles are
detected during Continuous Self-Test and stored in the EEC-IV memory.
Vehicles with a "CHECK ENGINE" or "SERVICE ENGINE SOOr-J" light concern must run
Quick Test and address all service codes present.
If all phases of the Quick Test, including Diagnosis By Symptom in Quick Test Step 19.0 I,
result in a PASS, it is likely that the problem is non-EEC-IV related and will be found
elsewhere. You should return to the Diagnostic Routines in Section 2.
When directed to a Pinpoint Test always read the cover page(s) for special notes and look
carefully at the Pinpoint Test Schematic.
After service, rerun Quick Test to ensure that service was effective.
* 80 warm-up cycles for some applications.

ALL RIGHTS RESERVED
142 EECIV Quick Test Procedures and Appendix
EEC-IV Quick Test - Procedures and Appendix
1.0 I VISUAL CHECK
Check vacuum hoses for damage and proper Yes ~ GO to Quick Test Step
connection. 12.01.
Check EEC-IV system wiring harness for proper
connections. No ~ SERVICE as necessary.
NOTE: If additional information is required on
Visual Checks, refer to Quick Test
Appendix.
Are all visual checks OK?
2.0 IVEHICLE
HOOKUP
PREPARATION AND EQUIPMENT
Apply parking brake. Yes ~ GO to Quick Test Step

13.01.
Place shift lever firmly in PARK (NEUTRAL for
manual transmissions).
No ~ REPEAT this test step.
Block drive wheels.
Turn off all electrical loads.
Connect appropriate test equipment to the Self-
Test connector in order to run Self-Test.
NOTE: If additional information Is required for
Vehicle Preparation and Equipment
Hookup, refer to Quick Test Appendix.
Is vehicle prepared to run Self-Test?

ALL RIGHTS RESERVED
EECIV Quick Test Procedures and Ap'pendix 143
3.0 I PERFORM KOEO SELF-TEST
Start engine and idle until vehicle is at operating Yes ~ If "CHECK ENGINE"
temperature. or "SERVICE ENGINE
SOON" light is on:
NOTE: If engine does not start or stalls after GO to Continuous
starting, continue to perform KOEO Self Memory code charts,
Test. Quick Test Step 18.0 I,
before addressing any
For 4.9L only, depress clutch for entire test step. other symptoms.
For 7.3L diesel only, depress throttle for entire
test step. If engine runs rough
or idles rough:
Key off, wait 1a seconds. GO to Pinpoint Test
Step 1521, except DIS/
Activate Self-Test. EDIS vehicles, GO to
Key on, engine off. Quick Test Step ~ .
NOTE: If additional information is required for If engine is a no

KOEO Self-Test, refer to Quick Test start:
Appendix. . . GO to Pinpoint Test
Step IA1 I, except
Record all KOEO and Continuous Memory Codes EDIS vehicles, GO to
received. Pinpoint Test Step
IAA11.
Is a PASS code "11" present in KOEO?
(11 ,11-1 a-any code) If these symptoms
NOTE: The first two "11' s" are PASS codes are not present:
from KOEO. The "10" is considered the GO to Quick Te~t Step
separator code between KOEO and 14.0 I, except 7.3L
diesel, GO to Quick
Continuous Memory.
Test Step 15.0 I.
No ~ If KOEO service
codes are received:
GO to KOEO code
charts, Quick Test Step
16.01.
If no service codes
are received:
GO to Pinpoint Test
Step IQA11.

ALL RIGHTS RESERVED
14-4 EEC-IV Quick Test Procedures and Appendix
3.1 ICHECK FOR CONTINUOUS MEMORY SERVICE

CODES 45, 46, AND 48
For DIS/EDIS vehicles only. Yes ~ For 1.9L MA:

GO to Pinpoint Test
Wer~ Continuous Memory service codes 45, 46, Step IN171.
or 48 received during KOEO Self-Test?
For 4.0L MA:
GO to Pinpoint Test
Step IN1SI.
For DIS:
GO to Pinpoint Test
Step IN131.
No ~ GO to Pinpoint Test
Step 1821.
4.0 I COMPUTED TIMING CHECK
Key off, wait 10 seconds. Yes ~ Go to Quick Test Step

15.01.
Activate Engine Running Self-Test.
Start engine. No ~ GO to Pinpoint Test
NOTE: If additional information is required for Step Ip21.
Engine Running Self-Test, refer to Quick
Test Appendix.
If engine starts but stalls or stalls during

Self-Test, GO to Pinpoint Test Step 1811 .
Engine Running Service Code 98 indicates

vehicle Is In Failure Mode Effects
Management (FMEM) and DID NOT PASS
KOEO On-Demand/Continuous Memory
Self-Test. Engine Running Self-Test cannot
be performed while in FMEM. Go to
Continuous Memory code charts, Quick
Test Step Is.o I.
Check computed timing after the last service code
has been displayed. The timing will remain fixed
for two minutes, unless Self-Test is deactivated.
NOTE: Computed timing is equal to base timing
plus 20 degrees BTDC with 3 degrees
tolerance. See vehicle decal for correct
base timing.
Is computed timing within specs?

ALL RIGHTS RESERVED
EEC-IV Quick Test Procedures and Appendix 14-5
5.0 1 PERFORM ENGINE RUNNING SELF-TEST .
Deactivate Self-Test. Yes ~ If any Continuous

Memory service .
Activate Engine Running Self-Test. codes were received
Start engine and idle until vehicle is at operating in Quick Test Step
temperature.
\a.ol:
NOTE: If additional information is required for GO to Continuous
Engine Running Self-Test" refer to Quick Memory code charts
Test Appendix. Quick Test Step 18.0 I.
Record all service codes displayed. 'If a Continuous

Memory PASS Code
NOTE: Engine Running Service Code 98 Indicates (11) was received in
vehicle Is In Failure Mode Effects Quick Test Step la.o I
Management (FMEM) and DID NOT PASS and no symptoms are
KOEO On-Demand/Continuous Memory present:
Self-Test. Engine Running' SelfTest cannot EEC-IV diagnostic
be performed while In FMEM.' Go to testing is complete.
Continuous Memory code charts, Quick
Test Step 18.0 I. If a Continuous
Memory PASS Code
Is a PASS Code (11) received during Engine (11) was received in
Running Self-Test? Quick Test Step la.o I
and symptoms are'
present:
GO to Diagnosis By
Symptom chart Quick
Test Step 19.0 I.
No ~ If .Engine Running
service codes are
received:
GO to Engine Running
code charts, Quick
Test Step 17.0 I.
If no service codes
are received:
GO t, Pinroint Test
Step QA1 .

ALL RIGHTS RESERVED
QUICK TEST STEP: Key On Engine Off

6.0
Code Charts
6.0 I PASSENGER CAR SERVICE CODE CHART

Pinpoint Test Step Direction
Key On
Engine Off 1.9L 1.9L 1.9L 2.3L 2.3L 2.3L 2.5L 2.9L 3.0L 3.0L 3.8L 3.8L 3.8L 5.0L 5.0L
Service Code MA OHC MA HSC SHO AXOD RWD SC MA
13 GO to
15 GO to
..
~
EFI
-
OB3
CFI
KB1
OB3
SEFI
-
OB3
EFI
-
OB3
EFI
-
OB3
EFI
-
OB3
CFI
KB1
OB3
EFI
-
OB3
EFI
-
OB3
SEFI SEFI SEFI
-
OB3
-
OB3
-
OB3
SEFI
-
OB3
SEFI
-
OB3
SEFI
-
OB3
19 GO to ~ - - OD5 OD5 OD5 OD5 - OD5 OD5 OD5 OD5 OD5 OD5 OD5 OD5
21 GO to ~ DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1
22 GO to ~ DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1
23 GO to ~ DH1 KB12 DH1 DH1 DH1 DH1 KB12 DH1 DH1 DH1 DH1 DH1 OH1 DH1 DH1
24 GO to ~ - DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1
26 GO to ~ DK1 - DC1 - DC1 - - - - DC1 - - DC1 - DC1
28 GO to ~ DA1 - - - - - - - - - - - - - -
31 GO to ~ - DL1 DL1 DD2 DN1 DL1 DN1 - DL1 DL1 DL1 DL1 DL1 DN1 DN1
32 GO to ~ - - - - DN25 - DN25 - - - - - - DN25 DN25
34 GO to ~ - DL8 DL8 - DN20 DL8 DN20 - DL8 DL8 DL8 DL8 DL8 DN20 DN20
35 GO to ~ - DL5 DL5 -
DN5 DL5 DN5 DL5 DL5 -DL5 DL5 DL5 DN5 DN5
52 GO to ~ - - - FF1 FF1 FF1 FF1 FF1 FF1 -FF1 - - - -
53 GO to ~ DH3 DH3 DH3 DH3 DH3 DH3 DH3 DH3 DH3 DH3 DH3 DH3 DH3 DH3 DH3
56 GO to ~ DK10 - DC20 - DC20 - - DC20- - - DC20 - DC20
57 GO to ~ - - - - - - - KH1 - - - - - - -
58 GO to ~ DA10 KB5 - - - - KB5 KH5 - - - - - - -
59 GO to ~ - - - - - - - KH10 - X97 T70 - - - -
62 GO to ~ - - - - - - - - T60 - - - - - -
63 GO to ~ DH10 DH10 DH10 DH10 DH10 DH10 DH10 DH10 DH10 DH10 DH10 DH10 DH10 DH10 DH10
66 GO to ~ DK20 - DC10 - DC10 - - - - DC10 - DC10 - DC10 -
67 GO to ~ FA1 FA1 FA1 FA1 FA1 FA1 FA1 FA1 T80 FA1 T81 FA1 FA1 FA1 FA1
68 GO to ~ DA20 KB9 - - - - KB9 - - - T90 - - - -
69 GO to ~ - - - - - - - - - - T75 - - - -
73 GO to ~ - KB20 - - - - KB20 - - - - - - - -
79 GO to ~ - - FA10 - FA10 - - - - FA10 FA10 FA10 FA10 FA10 FA10
81 GO to ~ - - - - - - - - - KT1 - - - KC8 KC8
82 GO to ~ - - - - - KC8 - - - - - - - KC8 KC8
83 GO to ~ - - KF1 DD17 - - X30 - X30 X15 X30 - X30 - -
84 GO to ~ - DL11 DL11 DD17 DN10 DL11 DN10 - DL11 DL11 DL11 DL11 DL11 DN10 DN10
85 GO to ~ - KD6 - - KD6 KD6 KD6 KD6 KD6 KD6 KD6 KD6 KD6 KD6 KD6
86 GO to ~ - - - - TB1 - - - - - - - - - -
87 GO to ~ - J7 J7 J7 J7 J7 X15 J7 X15 X15 X15 J7 J7 J7 J7
88 GO to ~ - - KF1 - - - X80 - X80 X80 X80 - X80 - -
89 GO to ~ - - - TB1 TB1 - - TB1 T50 - T50 - - - -
93 GO to ~ - KB11 - - - - KB11 - - - - - - - -
95 GO to ~ J20 J20 J20 - J20 J20 X90 - X90 X90 X90 J20 J20 J20 J20
NO CODES ~
CODES NOT
LISTED ~ Go to Pinpoint Test Step OA1

ALL RIGHTS RESERVED
QUICK TEST STEP:- Key On Engine- Off

6.0
Code Charts
6.0 I LIGHT TRUCK SERVICE CODE CHART

Key On
Engine Off 2.9L 4.0L
2.3L 2.9L 3.0L 4.9L 5.0L 5.8L 7.3L 7.5L
Service Code EFI EFI
MA MA EFI EFI EFI DIESEL EFI
EFI
EFI EFI
15 GO to ~ 083 083 083 Q83 083 083 083 083 083 083
16 GO to ~ - - - - N2 - - - - -
19 GO to ~ OD5 OD5 OD5 OD5 OD5 OD5 OD5 OD5 OD5 OD5
21 GO to ~ DA1 DA1 DA1 DA1 DA1 DA1' DA1 DA1 - DA1
22 GO to ~ DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1 DF1
23 GO to ~ DH1 DH1 DH1 DH1 DH1 DH1 DH1 DH1 DQ1 DH1
24 GO to ~ DA1 DA1 DA1 DA1 DA1 DA1 DA1 DA1 - DA1
26 GO to ~ DC1 - DC1 - DC1 TC30 - TC30 TC30 TC30
31 GO to ~ DN1 - - - - DN1 DN1 DN1 - DN1
32 GO to ~ DN25 - - - - DN25 DN25 DN25 - DN25
34 GO to ~ DN20 - - - - DN20 DN20 DN20 - DN20
35 GO to ~ DN5 - - - - DN5 DN5 DN5 - DN5
47 GO to ~ - - - - - TC10 - TC10 TC10 TC10
51 GO to ~ DA10 DA10 . DA10 DA10 DA10 DA10 DA10 DA10 - DA10
52 GO to ~ FFi - - FF1 - FF1 FF1 - - -
53 GO to ~ DH3 DH3 DH3 DH3 DH3 DH3 . DH3 DH3 002 DH3
56 GO to ~ DC20 - DC20 - DC20 TC40 - TC40 TC40 TC40
63 GO to ~ DH10 DH10 DH10 DH10 DH10 DH10 DH10 DH10 0010 DH10
66 GO to ~ DC10 - - - - TC50 - TC50 TC50 TC50
67 GO to ~ FA1 FA1 FA1 FA1 FA1 FA1 FA1 FA1 FA1 FA1
79 GO to ~ - - FA10 - FA10 - - - - - -
81 GO to ~ - - - - - KC8 KC8 KC8 - -
82 GO to ~ - - - - - KC8 KC8 KC8 - KC8
84 GO to ~ DN10 - - - - DN10 DN10 DN10 - DN10
85 GO to
86 GO to
~
~
-
T81
--
T81
-
T81
KD6
T81
KD6
T81
KD6
-
-
-
KD6
-
-
-
KD6
-
87 GO to ~ J7 J7 J7 J7 J7 J7 J7 J7 - J7
89 GO to ~ T81 T81 T81 T81 T81 - - - - -
91 GO to ~ - - - - - TC17 - TC17 TC17 TC17
92 GO to ~ - - - - - TC17 - TC17 TC17 TC17
93 GO to ~ - - - - - TC17 - TC17 TC17 TC17
94 GO to ~ - - - - - TC17 - TC17 TC17 TC17
95 GO to ~ J20 J20 J20 J20 J20 J20 J20 J20 - J20
96 GO to ~ J30 J30 J30 J30 J30 J30 J30 J30 - J30
97 GO to ~ - - - - - TC10 - TC10 TC10 TC10
98 GO to ~ - - - - - TC17 - TC17 TC17 TC17
99 GO to ~ - - - - - TC17 - TC17 TC17 TC17
NO CODES ~
CODES NOT
LISTED ~ Go To Pinpoint Test Step OA1

ALL RIGHTS RESERVED
QUICK TEST STEP: Engine Running

7.0
Code Charts

Engine Running 1.9L 1.9L 1.9L 2.3L 2.3L 2.3L 2.5L 2.9L 3.0L 3.0L 3.8L 3.8L 3.8L 5.0L 5.0L
EFI CFI SEFI EFI EFI EFI CFI EFI EFI SEFI SEFI SEFI SEFI SEFI SEFI
12 GO to
13 GO to KE1 KB23 KE1 KE1 KE1 KE1 KB23 KE1 KE1 KE1 KE1 KE1 KE1 KE1 KE1
KE15 KB1 KB15 KE15 KE15 KE15 KB1 KE15 KE15 KE15 KE15 KE15 KE15 KE15 KE15
16 GO to
KE22 KB30 - KE1 - - KB30 - - - - - - KE1 KE1

17 GO to KE26 KB30 - - - - KB30 - - - - - - - -
18 GO to P1 P1 P1 - P1 P1 - P1 P1 P1 P1 P1 P1 P1 P1
19 GO to KE25 KB26 - - - - - - - - - - - - -

21 GO to OA1 OA1 OA1 DA1 OA1 OA1 DA1 OA1 DA1 OA1 OA1 DA1 OA1 OA1 OA1
22 GO to OF1 DF7 DF1 OF7 DF1 DF7 OF? OF7 OF? OF1 OF7 DF7 OF1 OF7 OF1
23 GO to OH1 KB12 OH1 OH1 DH1 DH1 KB12 DH1 DH1 OH1 OH1 OH1 OH1 DH1 OH1
24 GO to
25 GO to -- OA1
-
OA1
-
DA1
DG1
OA1
OG1
OA1
-
DA1
-
DA1
-
DA1
OG1
DA1
OG1
DA1
-
DA1
-
DA1
DG1
DA1
-
OA1
-
26 GO to
OK1 - OC1 - DC1 - - - - OC1 - - OC1 - OC1
--
28 GO to OA1 - - - - - - - - - - - - - -
31 GO to OL21 DL21 D01 DN1 DL21 ON1 - OL21 OL21 DL21 OL21 DL21 DN1 DN1
32 GO to OL20 OL20 0011 DN25 OL20 DN25 - OL20 OL20 OL20 OL20 DL20 ON25 ON25
33 GO to
34 GO to --- OL30 OL30 D011 ON40 OL30 ON40
0L25 OL25 D011 ON50 DL25 ON50
-
-
DL30 OL30 DL30 DL30 OL30 DN40 ON40
OL25 DL25 OL25 DL25 OL25 ON50 ON50
35 GO to
OL25 OL25 0030 ON5 DL25 ON5 - DL25 OL25 OL25 OL25 OL25 ON5 ON5
41 GO to
42 GO to -H11
H23
H11
H23
H1
H1
H11
H23
H11
H23
H11
H23
H11
H23
H11
H23
H11
H23
H1
H1
H1
H1
H1
H1
H1
H1
H1
H1
H1
H1
44 GO to
- - - - - - - - - - - - - KC1 KC1
45 GO to
46 GO to - -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
KC1
KC1
KC1
KC1
47 GO to
KE20 - - - - - - - - - - - - - -
--
48 GO to KE21 - - - - - - - - - - - - - -
52 GO to - - - FF5 FF5 FF5 - FF5 FF5 FF5 - FF5 - -
55 GO to QE1 - - - - QE1 - - - - - - - -
56 GO to
58 GO to -
-
-
KB5
OC20
-
-
-
OC20
-
-
-
-
KB5
-
-
-
-
OC20
-
-
-
-
-
OC20
-
-
-
OC20
-
66 GO to ~ - - OC10 - OC10 - - - - OC10 - - OC10 - DC10

67 GO to - FA1 - - - - - - - - - - - - -
68 GO to - KB9 - - - - KB9 - - - T90 - - - -
72 GO to - - DC1 DF10 DC DF10 - OF10 OF10 X10 - - X10 - -
(Continued)

ALL RIGHTS RESERVED
-EECIV Quick Test Procedures and Appendix 149

7.0
Code Charts

Engine Running 1.9L 1.9L 1.9L 2.3L 2.3L 2.3L 2.5L 2.9L 3.0L 3.0L 3.8L 3.8L ~.8L 5.0L 5.0L
73 GO to ~ DH20 - DH20 DH20 DH20 DH20 -
DH20 DH20 DH20 - - DH20 - -
74 GO to ~ - - FD10 FD1 FD10 - FD10 - FD10 FD10 FD10 FD10 FD10 FD10 -
75 GO to .~ - - - FD5 - - - - - -
- - FD5 - -
76 GO to ~ DK30 - - - - - - - - - - - - - -
77 GO to ~ M1 - M1 M1 M1 M1 - Ml M1 M1 - M1 M1 M1 M1
84 GO to ~ - DL11 - - - - - - - - - - - - . -
85 GO to ~ - KD6 - - - - . - - - - - - - - -
87 GO to ~ - J7 - - - - - - - - - - - - -
91 GO to ~ - - - - - - - H1 - 'H1 H1 H1 H1 H1 H1
92 GO to ~ - - - - - - - H1 - H1 H1 H1 H1 H1 H1
94 GO to ~ - - - - - - - - - - - - - KC1 KC1
98 GO to ~ GO TO QUICK TEST STEP 3.0
99 GO to ~ - KB29 - - - - KB29 - - - - - - - -
NO CODES ~
CODES NOT'
LISTED ~ Go to Pinpoint Test Step QA1

ALL RIGHTS RESERVED

7.0
Code Charts

Engine Running 2.9L 4.0L
Service Code 2.3L 2.9L 3.0l 4.9l 5.0l 5.8l 7.3l 7.5l
EFI EFI
MA EFI
MA EFI EFI EFI DIESEL EFI
EFI EFI
12 GO to
13 GO to KEl
KE15
KEl
KE15
KEl
KE15
KEl
KE15
KEl
KE15
KEl
KE15
KEl
KE15
KEl
KE15
-
-
KEl
KE15
16 GO to
KEl - - - - - - - - -
18 GO to
21 GO to Pl
DAl
-
DAl
Pl
DAl
-
DAl
-
DAl
Pl
DAl
Pl
DAl
Pl
DA1
-
-
Pl
DAl
22 GO to
DF7 DF7 DF7 DF7 DF7 DF7 DF7 DF7 DF7 DF7
23 GO to
24 GO to DHl
DAl
DHl
DAl
DHl
DAl
DHl
DAl
DHl
DAl
DHl
DAl
DHl
DAl
DHl
DAl
DQl
-
DHl
DAl
25 GO to
- DGl - - - DGl DGl - - -
26 GO to
31 GO to DCl
DNl
-
-
DCl
-
-
-
DCl
-
TC30
DNl
-
DNl
TC30
DNl
TC30
-
TC30
DN1
32 GO to
DN25 - - - - DN25 DN25 DN25 - DN25
33 GO to
34 GO to DN40
DN50
-
-
-
-
-
-
-
-
DN40
DN50
DN40
DN50
DN40
DN50
-
-
DN40
DN50
35 GO to
DN5 - - - - DN5 DN5 DN5 - DN5
41 GO to
42 GO to H11
H23
H11
H23
Hll
H23
H11
H23
Hll
H23
H11
H23
H11
H23
Hl1
H23 -
- Hll
H23
44 GO to
- - - - - KCl KCl KCl - KCl
45 GO to
46 GO to -
-
-
-
-
-
-
-
-
-
KCl
KCl
KCl
KCl
KCl
KCl
-
-
KCl
-
52 GO to
FF5 - - FF5 - FF5 FF5 - - -
56 GO to
65 GO to DC20
-
-
-
DC20
-
-
-
DC20
-
-
TC10
-
-
-
TC10
-
TC10
-
TC10
66 GO to
DC10 - DC10 - DC10 - - - - -

72 GO to DF10 DF10 DF10 DF10 DF10 DF10 DF10 DF10 - DF10
73 GO to DH20 DH20 DH20 DH20 DH20 DH20 DH20 DH20 - DH20
74 GO to FD10 FD10 FD10 FD10 FD10 FD10 - FD10 FD10 FD10
77 GO to
Ml Ml Ml Ml Ml Ml Ml Ml - Ml
98 GO to
GO TO QUICK TEST STEP 3.0
NO CODES
CODES NOT
LISTED
Go to Pinpoint Test Step QA1

ALL RIGHTS RESERVED
QUICK TEST STEP: Continuous Memory

8.0
Code Charts

Continuous
Memory 1.9L 1.9L 1.9L 2.3L 2.3L 2.3L 2.SL 2.9L 3.0L 3.0L 3.8L 3.8L 3.8L 'S.OL S.OL
EFI CFI SEFI EFI EFI EFI CFI EFI EFI SEFI SEFI SEFI ~EFI SEFI SEFI
13 GO to
14 GO to
15 GO to
- KB90 -
~ N1 N1 N1
~ QB1 QB1 QB1
-
N1
QB1
-
N1
QB1
-
N1
QB1
KB90 -
N1 N1
QB1 QB1
-
N1
QB1
-
N1
QB1
-
N1
QB1
-
N1
QB1
-
N1
QB1
-
N1
QB1
-
N1
QB1
18 GO to ~ N4 N4 N3 N4 N4 N4 N4 N4 N3 - N4 N4 N3 N4 N4
19 GO to ~ - -
DR1 - - - -- N10 - - - N10 - -
22 GO to ~ DF90 DF90 DF90 DF90 DF90 DF90 DF90 DF90 DF90 DF90 DF90 DF90 DF90 DF90 DF90
23 GO to ~ - KB97 - - - - KB97 - - - - - - - -
26 GO to ~ DK98 - - - - - - - - - - - - - -
29 GO to ~ - - DP1 - DP1 DP1 DP1 DP10 T1 OP1 T1 DP1 DP1 DP1 DP1
31 GO to
32 GO to
33 GO to

~
~
-
-
-
DL90 DL90 D090 DN91 DL90 DN91
DL94 DL94
DL97 DL97
-
-
DN90 DL94 DN90
DN95 DL97 DN95
-
-
-
DL90 DL90 OL90 DL90 DL90 DN91 DN91
DL94 DL94 DL94 DL94 DL94 DN90 DN90
DL97 DL97 DL97 DL97 DL97 DN95 DN95
34 GO to ~ - DL93 OL93 - DN98 DL93 DN98 - OL93 DL93 OL93 DL93 DL93 DN98 ON98
35 GO to ~ - DL90 DL90 - DN93 DL90 DN93 - DL90 DL90 DL90 DL90 DL90 DN93 DN93
38 GO to ~ - KB91 - - - - KB91 - - - - - - - -
39 GO to ~ - - - - - - - - T30 - T30 - - - -
41 GO to ~ H30 H29 H29 H29 H29 H29 H29 H29 H29 H29 H29 H29 H29 H29 H29
42 GO to ~ H30 - - - - - - - - - - - - - -
43 GO to ~ H30 - - - - - - - - - - - - - -
45 GO to ~ - - N17 - - - - - - N13 - - N13 - -
46 GO to ~ - - N17 - - - - - - N13 - - N13 - -
48 GO to ~ - - - - - - - - N13 - - - N13 - -
49 GO to ~ - - - - - - - P10- - - - P10 - -
53 GO to ~ DH90 KB93 DH90 DH90 DH90 DH90 KB93 DH90 DH90 DH90 DH90 DH90 DH90 DH90 DH90
56 GO to ~ DK90 - DC20 - DC20 -- -
- DC20 - - DC20 - DC20
57 GO to ~ - - - - - - - - T40 - T40 - - - -
58 GO to ~ DA90 - - - - - - - - - - - - - -
59 GO to ~ - - - - - - - - T20 X95 T20 - - - -
63 GO to ~ DH94 KB97 DH94 DH94 DH94 DH94 KB97 DH94 DH94 DH94 DH94 DH94 DH94 DH94 OH94
65 GO to ~ H30 - - -- -- - - - - - - - -
(Continued)

ALL RIGHTS RESERVED

8.0
Code Charts

Continuous
Memory 1.9L 1.9L 1.9L 2.3L 2.3L 2.3L 2.5L 2.9L 3.0L 3.0L 3.8L 3.8L 3.8L 5.0L S.OL
66 GO to ~ DK93 - DC10 - DC10 - - - - DC10 - - DC10 - DC10
67 GO to ~ FA1 - FA1 - FA1 - - - - FA1 - - FA1 - -
68 GO to ~ DA90 - - - - - - - - - T90 - - - -
69 GO to ~ - - - - - - - - T10 - T10 - - - -
70 GO to ~ - - - - - - - - - - ML25 - - - -
71 GO to ~ QD1 KB92 - - - - KB92 - - - ML25 - - - -
72 GO to ~ QD4 - - - - - - - - - ML25 - - - -
83 GO to ~ - - - - - - - - - X15 - - - - -
85 GO to ~ H30 - - - - - - - - - - - - - -
86 GO to ~ H30 - - - - - - - - - - - - - -
87 GO to ~ - J95 J95 - J95 J95 X104 J95 X104 X104 X104 J95 J95 J95 J95
91 GO to ~ - - - - - - - H29 - H29 H29 H29 H29 H29 H29
NO CODES ~
CODES NOT
LISTED ~ Go to Pinpoint Test Step QA1

ALL RIGHTS RESERVED

8.0
Code Charts

Continuous
Memory 2.9l 4.0L
2.3L 2.9L 3.0L 4.9L. 5.0L 5.8L 7.3L 7.5L
Service Code EFI . -.MA . MA . EFI
EFI EFI EFI EFI DIESEL EFI
EFI EFI
14 GO to
15 GO to N1
QB1
N1
QB1
N1
QB1
N1
QB1
Sec 13
QB1'
N1
QB1
N1
QB1
N1
QB1
DJ1
QB1
N1
QB1
18 GO to
Sect 13 N4 N4 N4 N3 N4 N4 N4 - N4
19 GO to
22 GO to Sect 13
DF90
-
DF90
-
DF90
-
DF90
-
DF90
-
DF90
-
DF90
-
DF90
-
DF90
-
DF90
28 GO to
N3 - - - - - - - - -
29 GO to
31 GO to DP1
DN91
DP1
-
DP1
-
DP1
-
DP1
-
DP1
DN91
DP1
DN91
DP1
DN91
DP1
-
DP1
DN91
32 GO to
33 GO to
DN90
DN95
-
-
-
-
-
-
-
-
DN90
DN95
DN90
DN95
DN90
DN95
-
-
DN90
DN95

34 GO to DN98 - - - - DN98 DN98 DN98 - DN98
35 GO to DN93 - - - - DN93 DN93 DN93 - DN93
41 GO to
45 GO to H29
-
H29
-
H29
-
H29
-
H29
N15
H29
-
H29
-
H29
-
-
-
H29
-
48 GO to
N3 - - - - - - - - -
49 GO to
51 GO to -
DA90
-
DA90
-
DA90
-
DA90
-
DA90
TC90
DA90
-
DA90
TC90
DA90
TC90
-
TC90
DA90
53 GO to
DH90 DH90 DH90 DH90 DH90 DH90 DH90 DH90 DQ90 DH90

54 GO to DA90 DA90 DA90 DA90 DA90 DA90 DA90 DA90 - DA90
56 GO to DC20 - DC20 - DC20 TC90 - TC90 TC90 TC90
59 GO to - - - - - TC90 - TC90 TC90 TC90

62 GO to - - - - - TC90 - TC90 TC90 TC90
63 GO to DH94 DH94 DH94 DH94 DH94 DH94 DH94 DH94 DQ94 DH94

66 GO to DC10 - DC10 - DC10 TC90 - TC90 TC90 TC90
67 GO to - - FA1 - FA1 TC90 - TC90 TC90 TC90

69 GO to - - - - - TC90 - TC90 TC90 TC90
87 GO to J95 J95 J95 J95 J95 J95 J95 J95 - J95
88 GO to N20 - - - - - - - - -

95 GO to J90 J90 J90 J90 J90 J90 J90 J90 - J90
96 GO to J93 J93 J93 J93 J93 J93 J93 J93 - J93
99 GO to - - - - - TC90 - TC90 TC90 TC90
NO CODES
CODES NOT
LISTED
Go to Pinpoint Test Step QA1

ALL RIGHTS RESERVED
QUICK TEST STEP: Diagnosis By Symptom 9.0
9.0 I DIAGNOSIS BY SYMPTOM
SPECIAL NOTES:
Verify that a Pass Code 11 was received in Key On
Engine Off, Engine Running and Continuous Self-Tests
before continuing with this test.
If a symptom is present and the EEC system is
suspected, Go to part B of Diagnosis By Symptom.
If the EEC system is not suspected, GO to Section 2,
Diagnostic Routines.

ALL RIGHTS RESERVED
9.0 I PASSENGER CAR DIAGNOSIS BY SYMPTOM

Symptom Pinpoint Test Step Direction
1.9L 2.3L 2.3L 2.3L 3.0L 3.8L 3.8L 3.8L 5.0L
1.9L 1.9L MA OHC MA HSC 2.5L 2.9L 3.0L SHO AXOD RWD SC 5.0L MA
Engine runs rough
or misses
Lack of power
Rough idle 52 52 52* 52* 52 52 52 52 52 52* 52 52 52** 52 82*
Erratic rpm
5urges
Hesitation
5talls in 5elf-Test
51 51 51 52 51 51 52' 51 51 51 51 51 51 51 51
Engine stalls
5tall during parking
maneuvers - FF3 - FF3 FF3 -' FF3 KH12 FF3 FF3 FF3 - - - -
5urges with A/C on
at idle - - - KM30 KM30 KM30 - - - - - - - - -
A/C does not cut
off under WOT KM15 KM15 KM15 KM15 KM15 KM15 X52
. - X52 X52 X52 KM15 X52 KM15 KM15
conditions
A/C not functioning KM1 KM1 KM1 KM1 KM1 KM1 X50 - X50 X50 X50 KM1 X50 KM1 KM1
A/C compressor
runs continuously
- - - KM35 KM35 - -' - - - - - - - -
High idle speeds on
each restart may be
accompanied by
spark knock for up
KA1 - - - - - - - - - - - - - -
to 3-5 minutes after
a start
Low idle with A/C
FA11 FA11 FA11 FA11 FA11 FA11' FA11 KH12 FA1.1 FA11 FA11 FA11 FA11 FA11 FA11
On
High idle in Drive,
automatic trans. only - - '- - - - FA20 FA20 - - - FA20 - - -
(Continued)
* Verify that MAF sensor is properly connected.
** If engine idles rough, go to Section 8 and check. for intercooler leaks.

ALL RIGHTS RESERVED

- 1.9L 2.3L 2.3L 2.3L 3.0L 3.8L 3.8L 3.8L 5.0L

1.9L 1.9L MA OHC MA HSC 2.5L 2.9L 3.0L SHO AXOD RWD SC 5.0L MA
Shift indicator light
always On or Off
KL1 KL1 KL1 - - KL1 KL1 - - - - - KL1 - KL1
"CHECK ENGINE"
or "SERVICE
ML1 ML1 ML1 ML1 ML1 ML1 ML1 ML1 ML1 ML1 ML1 ML1 ML1 ML1 ML1
ENGINE SOON"
light always on
"CHECK ENGINE"
or " SERVICE
ENGINE SOON"
light never on
"CHECK ENGINE" /
"CHECK DCL" - - - - - - - - - - ML25 - - - -
Message On
"CHECK ENGINE"
Message On - - - - - - - - - - ML20 - - - -
"CHECK ENGINE"
or "SERVICE
ENGINE SOON"
light ~n intermittently
"CHECK ENGINE"
or "SERVICE
ENGINE SOON" ML15 ML15 ML15 ML15 ML15 ML15 ML15 ML15 ML15 ML15 ML15 ML15 ML15 ML15 ML15
light flashing with
erratic idle
Lack of power at
wide open throttle - - - - - - - - - KT6 - - - - -
Lack of cruise
control and decel - - - - - - DP1 - - - - - - - -
stalls
Vehicle tachometer
not operating - - - - - - - - - N3 - - N3 - -
Transmission will not
shift into overdrive - - - - TB1 1 - TB1 1 - - - - - - - -
No transmission
lock-up. Cruise rpm
slightly higher than - - - - TB 2 - TB1 2 - - - - - - - -
normal (about 300
rpm)
(Continued)
1 Use Code 86 Diagnosis
2 Use Code 89 Diagnosis

ALL RIGHTS RESERVED

1.9L 2.3L 2.3L 2.3L 3.0L 3.8L 3.8L 3.8L S.OL
1.9L 1.9l MA OHC MA HSC 2.Sl 2.9L 3.0l SHO AXOD RWD SC S.Ol MA
Stumble after hot
H2O H2O H2O H2O H2O H2O H2O H2O H2O H2O H2O H2O H2O H2O H2O
restart
Engine will not
restart - QE1 - - - - QE1 - - - - - - - -
Fuel pump runs with
engine off - - - J22 - - X14 J22 X14 X14 - - J22 J22 -
Gasoline fumes
under hood
KD1 KD1 - - KD1 KD1 KD1 KD1 KD1 KD1 KD1 KD1 KD1 KD1 KD1
Black Exhaust
H29 H29 H29 H29 H29 H29 H29 H29 H29 H29 H29 H29 H29 H29 H29
Smoke
KA1 DG1 DG1 DG1
or or or or
Spark knock
SEC.
- KP1
SEC. SEC. - - KH3
SEC.
KP1 - - KP1 - -
6 6 6 6
X40
No engine cooling
fan - - KF10 - - - MTX - - X40 - - - - -
ONLY
Low speed cooling
fan does not
operate
High speed cooling X19
fan does not - - KF10 - - - CLC - X19 - X19 - X19 - -
operate ONLY
Low or high speed
cooling fan does not
operate
Low or high speed
cooling fan always - - KF25 - - - X35 - X35 X35 X35 - X38 - -
on
High Boost Pressure - - - - - - - - - - - - KS6 - -

ALL RIGHTS RESERVED
9.0 I LIGHT TRUCK DIAGNOSIS BY SYMPTOM

4.0l
2.3l 2.9l 3.0l 4.9l S.Ol S.8l 7.3l 7.Sl
MA
EFI EFI EFI EFI EFI EFI DIESEL EFI
EFI
Engine runs rough or misses
Surges
Lack of power S2 S2* S2 S2* S2 S2 S2 - S2
Rough idle
Erratic rpm
Engine Stalls
Stalls in Self-Test
S1 S1 S1 S1 S1 S1 S1 - S1
Stall during parking maneuvers FF3 FF3 FF3 - FF3 FF3 - - -

A/C Compressor runs
continuously
KM35 - - - FA18 - - - -
Surges with A/C on at idle KM30 - - - - - - - -
A/C does not cut off under
WOT conditions
KM15 KM15 KM15 - - - - - -
A/C not functioning KM1 KM1 KM1 KM1 FA17 FA17 FA17 FA17 FA17
Low idle with A/C On FA11 FA11 FA11 FA11 FA11 FA11 FA11 - FA11
"CHECK ENGINE" or "SER-
VICE ENGINE SOON" light al- ML1 ML1 ML1 ML1 ML1 ML1 ML1 - ML1
ways on
VICE ENGINE SOON" light ML5 ML5 ML5 ML5 MLS ML5 MLS - MLS
never on
VICE ENGINE SOON" light on ML10 ML10 ML10 ML10 ML10 ML10 ML10 - ML10
intermittently
VICE ENGINE SOON" light ML15 ML1S ML1S ML15 ML1S ML15 ML15 - ML15
flashing with erratic idle
Stumble after hot restart H2O H2O H2O H2O H2O H2O H2O - H2O
(Continued)
Verify that MAF sensor is properly connected.

ALL RIGHTS RESERVED
QUICK TEST STEP: Diagnosis By Symptom' 9~O
9.0 I LIGHT TRUCK DIAGNOSIS BY SYMPTOM

4.0L
2.3L 2.9L 3.0L 4.9L S.OL S.8L 7.3L 7.SL
MA
EFI EFI EFI EFI EFI EFI DIESEL EFI
EFI
Fuel pump runs with engine off J22 - - - - - - - -
Gasoline fumes under hood - - KD1 KD1 KD1 - DK1 - KD1
Exhaust Order
Black Smoke
H29 H29 H29 H29 H29 H29 H29 - H29
SEC. 6 DG1 or DG1 or

Spark knock
or KP1
- - - SEC. 6 SEC. 6 - - -
Poor idle quality
Rolling idle
Shifts harshly
- - DP1 - - - - DJ1 -
Poor fuel economy
High idle
A/C not functioning - - - - FA15 FA15 - - FA15
Overdrive Cancel Indicator

(OCI) light always off (E40D
only)
- - - - TC13 - TC13 TC13 TC13
Hard to Start (cold) N25 - - - - - - - -

Tachometer Inoperative
(Vehicles with Tachometer)
- - - - - - - DJ1 -
4 x 4 Low Indicator
Light Always Off
(always on with sluggish
- - - - TC11 - TC11 TC11 TC11
shift) - E40D Only
Tachometer indicates
a low vehicle rpm - - - - - - - DJ1 -

ALL RIGHTS RESERVED
14-20 EEe-IV Quick Test Procedures and Appendix
APPENDIX: Visual Check
SPECIAL NOTES:
Correct results of the QUICK TEST are dependent on
the proper operation of related non-EEC-IV components.
It may be necessary to disconnect or disassemble har-
ness connector assemblies to do some of the inspec-
tions. Pin locations should be noted before disassembly.
VISUAL CHECK
1. Inspect the air cleaner and inlet ducting.
2. Check all engine vacuum hoses for damage, leaks, cracks, blockage, proper routing, etc.
3. Check EEC-IV system wiring harness for proper connections, bent or broken pins,
corrosion, loose wires, proper routing, etc.
4. Check the processor, sensors and actuators for physical damage.
5. Check the engine coolant for proper level.
6. Check the transmission fluid level and quality.
7. Make all necessary repairs before continuing with QUICK TEST.

ALL RIGHTS RESERVED
EEC-IV Quick Test Procedures and Appendix 1421
APPENDIX: Vehicle Preparation and

Equipment Hookup
SPECIAL NOTES:
Refer to the illustrations for Self-Test connector pin ori-
entation and VOM and STAR hookup.
After the equipment is properly hooked up, proceed to
Quick Test Step 13.0 I.
VEHICLE PREPARATION
1. Perform ALL safety steps required to start and run vehicle tests - apply parking brake,
place shift lever firmly into PARK position (NEUTRAL on manual transmission), block drive
wheels, etc.
2. Turn off ALL electrical loads - radios, lights, A/C-heater blower fans, etc.
USING THE STAR TESTER
1. Turn the ignition key off.
2. Connect the color coded adapter cable to the STAR tester.
3. Connect the adapter cable leads to th~ pr?per Self-Test connectors.
4. Connect the timing light.
STAR HOOKUP (WITH VOLTMETER HOOKUP (WITH

ADAPTER CABLE ASSEMBLY) JUMPER WIRE)
TO VEHICLE
HARNESS
-1=====~=,-......
""lIIII
VEHICLE
SELFTEST
CONNECTORS
STAR
SERVICE
CONNECTORS
000
c::::J 0
o VEHICLE
B A11608-A
BATTERY
A8335-C
USING AN ANALOG VOLTIOHM METER (VOM)

1. Turn the ignition key off.
2. Set the VOM on a DC voltage range to read from 0 to 15 volts.
3. Connect the VOM from the battery positive post to the Self-Test Output pin of the large
Self-Test connector.
4. Connect the timing light.

ALL RIGHTS RESERVED
APPENDIX: Vehicle Preparation and

Equipment Hookup
USING THE "CHECK ENGINE" or "SERVICE ENGINE SOON" LIGHT (MIL)
No special equipment hookup is required.
USING THE MESSAGE CENTER ON CONTINENTAL APPLICATIONS ONLY
MESSAGE CENTER (CONTINENTAL ONLY)

"CHECK ENGINE" OR
"SERVICE ENGINE
SOON" LIGHT
(WITH JUMPER WIRE)
TO 1===~~~""""
VEHICLE ......
HARNESS
SELF-TEST---i~
CONNECTOR
SELFTEST
INPUT (STI)
A11516-C
USING THE OVERDRIVE CANCEL INDICATOR LIGHT (OCIL}/TRANSMISSION

MALFUNCTION INDICATOR LIGHT (TMIL) ON 7.3L DIESEL ENGINES ONLY

ALL RIGHTS RESERVED
EEC-IV Quick Test Procedures a'nd Appendix 14-23
APPENDIX: Key On Engine Off

Self-Test
PERFORMING THE KEY ON ENGINE OFF SELF-TEST
SPECIAL NOTES:
It may be necessary to service non-EEC-IV faults before
running Quick Test. Refer to Section 2.
Continuous Memory, Codes recorded in this step will be
used for diagnosis in Step 15.0 I after a PASS code 11
is received in both the Key On Engine Off and the En-
gine Running Self-Tests.
Deviation from this procedure may cause the output of
false codes.
Refer to Quick Test Appendix for further information on
how to read, code output.
On all vehicles equipped with a 4~9L ENGINE, the clutch
must be depressed during the Key On Engine Off Self-
Test.
On all vehicles equipped with a 7.3L DIESEL ENGINE,
the throttle must be depressed (WOT) during the entire
Key On Engine Off Self-Test.
HOW TO RUN THE KEY ON ENGINE OFF SELF-TEST
1001
Veri~at the vehicle has been properly prepared a~cording to QUICK TEST STEPS [LQ]
and~.
Start engine and run until at operating temperature.
Turn engine off and. wait 10 seconds.

,
Activate Self-Test.
STAR Tester: Latch the center button in the down position.
Analog VOM: Jumper STI to SIG RTN at the Self-Test connectors.
"CHECK ENGINE" or "SERVICE ENGINE SOON" Light (MIL): Jumper STI to SIG RTN
at the Self-Test connectors. Service Codes will be flashed on the "Check Engine" or
"SERVICE ENGINE SOON" Light.
Message Center,..{Continental Applications Only): Refer to Appendix: Self-Test.
Place ignition key in the ON position.

For 7.3L Diesel vehicles only, depress the throttle.
Record all service codes displayed.
IDON'Tl
Depress throttle during Key On Engine Off Self-Test -on gasoline engine applications.

ALL RIGHTS RESERVED
APPENDIX: Engine Running

Self-Test
PERFORMING THE ENGINE RUNNING SELF TEST
SPECIAL NOTES:
If the engine starts but stalls, or stalls during Self-Test,
Go to Pinpoint Test Step [I1] .
On vehicles equipped with the Brake On/Off Switch
(BOO), the brake pedal MUST be depressed and re-
leased AFTER the ID code.
On vehicles equipped with the Power Steering Pressure
Switch (PSPS), within 1 to 2 seconds after the ID code,
the steering wheel must be turned at least one-half turn
and released.
On vehicles equipped with E40D transmission, the
Overdrive Cancel Switch (OCS) must be cycled after the
ID code.
The Dynamic Response code is a single pulse (or a 10
code on the STAR Tester) that occurs 6-20 seconds af-
ter the engine running identification code. (See APPEN-
DIX: Code Output Format.)
When the Dynamic Response code occurs, perform a
brief wide-open throttle.
HOW TO RUN THE ENGINE RUNNING SELF-TEST
IDOl
Deactivate Self-Test.
Start and run engine at 2,000 rpm for two minutes. This action warms up the EGO sensor.
Turn engine off, wait 10 seconds.
Activate Self-Test.
Start engine.
After the ID code, depress and release the brake pedal if appropriate. See Special Note
above.
After the ID code, within 1 to 2 seconds, turn the steering wheel at least one-half turn and
then release it, if appropriate. See Special Note above.
If a Dynamic Response Code occurs, perform a brief wide-open throttle (WOT).
Record all service codes displayed.
IDON'TI
Depress the throttle unless a Dynamic Response Code is displayed.

ALL RIGHTS RESERVED
EECIV Quick Test Procedures and Appendix 14-25
APPENDIX: Continuous Memory

Self-Test
CONTINUOUS MEMORY CODES
SPECIAL NOTES:
If Continuous Memory is a PASS Code 11 and a symp-
tom is present, GO to Quick Test Step 19.0 I.
DETERMINING THE CONTINUOUS MEMORY CODES -TO BE SERVICED
Refer to the Continuous Memory Codes recorded in Quick Test Step 13.0 I.
The cause of some of the Continuous Memory Codes may have been eliminated during
either Key On Engine Off or Engine Running Self-Test service. To address the remaining
Continuous Memory codes, go to Quick Test Step 18.0 I. If none,' clear Continuous Memory.

ALL RIGHTS RESERVED
APPENDIX: Self-Test
Description
The Self-Test is divided into three specialized tests: Key On Engine Off Self-Test, Engine
Running Self-Test, and Continuous Self-Test. The Self-Test is not a conclusive test by itself,
but is used as a part of the functional Quick-Test diagnostic procedure. The processor stores
the Self-Test program in its permanent memory. When activated, it checks the EEC-IV system
by testing its memory integrity and processing capability, and verifies that various sensors and
actuators are connected and operating properly.
The Key On Engine Off and Engine Running Self-Tests are functional tests which only detect
faults present at the time of the Self-Test. Continuous Self-Test is an ongoing test that stores
fault information for retrieval at a later time.
KEY ON ENGINE OFF SELF-TEST
At this time, a test of the EEC-IV system is conducted with power applied and engine at rest.
For Self-Test to detect errors in the Key On Engine Off Self-Test mode, the fault must be
present at the time of testing. For intermittents, refer to Continuous Memory Codes.
SEPARATOR PULSE
A single 1/2 second separator pulse is issued 6-9 seconds after the last Key On Engine Off
Test code. Then, 6-9 seconds after the single 1/2 second separator pulse, the Continuous
Memory Codes will be issued.

Continuous Memory Codes are issued as a result of information stored during continuous Self-
Test, while the vehicle was in normal operation. These codes are displayed only during Key
On Engine Off testing and after the separator code.
NOTE: The separator code and Continuous Memory Codes follow Key On Engine Off
Testing codes ONLY.
ENGINE RUNNING SELF-TEST

At this time, a test of the EEC-IV system is conducted with the engine running. The sensors
are checked under actual operating conditions and at normal operating temperatures. The
actuators are exercised and checked for expected results.
ENGINE IDENTIFICATION CODES (10 CODES)
Engine ID codes are issued at the beginning of the Engine Running Self-Test and are one-
digit numbers represented by the number of pulses sent out. For gasoline engines, the engine
10 code is equal to one-half the number of engine cylinders (Le. 2 pulses = 4 cylinders). For
the 7.3L Diesel engine, the ID code = 5. These codes are used to verify the proper processor
is installed and that the Self-Test has been entered.
DYNAMIC RESPONSE CHECK
The dynamic response check verifies the movement of the TP, VAF, MAF and MAP sensors
during the brief Wide-Open Throttle (WOT) performed during the Engine Running Self-Test. The
signal for the operator to perform the brief WOT is a single pulse or 10 code on the STAR
Tester.

ALL RIGHTS RESERVED
EECIV Q~lck Test Procedures and Appendix 1427
APPENDIX: Self-Test
Description
POWER STEERING PRESSURE SWITCH TEST
On vehicles equipped with Power Steering Pressure Switch (PSPS), the steering wheel must be
turned one-half turn and released AFTER the 10 Code has been displayed. This tests the
ability of the EEC-IV system to detect a change of state in the Power Steering Pressure
Switch.
BRAKE ON/OFF SWITCH TEST
On vehicles equipped with Brake ON/OFF Switch (BOO), the brake pedal MUST be depressed
and released AFTER the 10 Code has been displayed. This tests the ability of the EEC-IV
system to detect a ch~nge of state in the Brake ON/OFF Switch.
OVERDRIVE CANCEL SWITCH TEST
On vehicles equipped with Overdrive Cancel Switch (OCS), the switch must be cycled after the
10 code has been displayed. This tests the ability of the EEC-IV system to detect a change of
state in the Overdrive Cancel Switch.
','

ALL RIGHTS RESERVED
APPENDIX: Code Output

Format
SERVICE CODES
The EEC-IV system communicates service information through the Self-Test service codes.
These service codes are two-digit numbers representing the results of Self-Test.
The service codes are transmitted on the Self-Test output (STO) line found in the vehicle Self-
Test connector. They are in the form of timed pulses, and are read by the technician on a
voltmeter, STAR tester, "CHECK ENGINE" or "SERVICE ENGINE SOON" Light (MIL) or on
the Continental message center.
SELF-TEST OUTPUT CODE FORMAT
KEY ON ENGINE OFF AND CONTINUOUS MEMORY CODES
DIGIT PULSES ARE 1/2 SECOND "ON" AND 1/2 SECOND "OFF"
ANALOG
METER:
EACH PULSE
EQUALS
1 METER '-v-' ~ '-v-' --.,.....- ~ '-v-'
SWEEP
j ~
FAST CODES KEY ON. ENGINE OFF CODES
'V
STAR STAR
:11 :11
NOTE: CONTINUOUS CODES WILL ONLY BE OUTPUTTED DURING KEY ON ENGINE OFF SELF-TEST
Figure 1 Key On Engine Off and Continuous Memory Code Format

SELF-TEST OUTPUT CODE FORMAT
ENGINE RUNNING CODES
DIGIT PULSES ARE 1/2 SECOND "ON" AND 112 SECOND "OFF"
2 = 4 CYL.
----..........------
6-20 SECONDS
~
3 = 6 CYL. FAST
4 = 8 CYL.
ENGINE RESPONDS
TEST
CODES
5 = 7.3LDIESEL ENGINE RUNNING "GOOSE ENGINE
ENGINE RUNNING
ID PULSE CODES
NOW" CODE
STAR STAR STAR

:20 :10 :11
A8204-D
Figure 2 Engine Running Self-Test Code Format

Fast Codes
Fast codes are issued prior to regular service codes. These codes contain the identical
information as the regular service codes but are transmitted at 100 times the normal rate.
These codes are interpreted by special equipment at the end of the assembly line by the
Body and Assembly Division.
Some meters in service detect these codes as a short burst of information (slight meter
deflection). .

ALL RIGHTS RESERVED
APPENDIX: Continuous
Self-Test
The Continuous Memory service codes are separated from the Quick Test Key On Engine Off
codes by a single separator pulse, Figure 3.
CODE 11 CODE 11 CODE 10 CODE 11 CODE 11
6-9 SECONDS 6-9 SECONDS
SEPARATOR
STAR
:10
A8114-C
Figure 3 Continuous Memory Code Format
During this mode of testing the EEC-IV Processor continuously monitors inputs for opens and
shorts. The Continuous Memory Codes must be retrieved within* 40 engine temperature warm
up cycles. On the 41 st or 81 st Engine Temperature cycle, the service code will be
automatically erased. The' Continuous Memory Codes can also be erased by deactivating 5elf-
Test while the service codes are being outputted.
* 80 engine temperature ,warm up cycles for some applications.

ALL RIGHTS RESERVED
1430 EEC-IV Quick Test Procedures and Appendix
APPENDIX: Self-Test With

STAR Tester
READING CODES-SELF-TEST AUTOMATIC READOUT (STAR) TESTER
After hooking up the STAR tester and turning on its power switch, the tester will run a display
check and the numerals 88 will begin to flash in the display window (Figure 4). A steady 00
will then appear to signify that the STAR tester is ready to start the Self-Test and receive the
test's service codes.
To receive the service codes, press the push button at the front of the STAR tester. The
button will latch down, and a colon will appear in the display window in front of the 00
numerals. The colon must be displayed to receive the service codes.
If, for any reason, the technician wishes to clear the display window during the Self-Test, he
must turn off the vehicle's engine, press the tester's push button once to unlatch it (colon will
disappear), then press the button again to latch down the button (colon will appear again).
The STAR tester will display the last service code received, even after disconnecting it from
the vehicle. It will hold the service code on the display until the power is turned off or the
push button is unlatched and relatched.
For a detailed description of the STAR tester and the variety of tests that can be run, refer to
the instruction manual provided with the tester.
.,,-,
'-I '-'
..,.-,
COLON DISPLAY
I..'&.'
~FlASHES
COLON MUST BE DISPLAYED

10 RECEIVE SERVICE CODES.
STEAOY~
.. -, -,
LD BAT INDICATOR
L.OBAT
~ IF LD BAT SHOWS STEADILY WITH
SERVICE CODE. REPLACE TESTER'S
~ tV BATTERY.
Figure 4 Star Tester Output Code Format

ALL RIGHTS RESERVED

SUPER STAR II Tester
The SUPER STAR II Tester can read fast codes as well as slow codes, and can be used on
Ford EEC-IV as well as MCU and MECS systems. A built-in Self-Test memory will retain the
codes as t~ey are received. !he SUPER STAR II tester also contains a beeper for running
the wiggle tests.
After hooking up the SUPER STAR II tester and turning it on, the SUPER STAR II will briefly
display 888. It will also light all the prompts on the left side of the display and the speaker
will beep. When the tester is ready, both the STI-LO and STO-LO will be on, but the readout.
will be blank if the vehicle key is off.
Key On Engine Off (KOEO) SelfTest

1. Plug in both connectors of the tester to. the mating connectors of the vehicle.
2. Determine the type of system you have (EEC-IV or MECS) and set the switch to the
proper type.
. .
3. Select fast code mode or slow code mode with the mode selector switch.
4. Turn on the power to the tester. . ..
5. Depress the test button on the tester to the test position.
6. Turn on the vehicle ignition key.
The tester will now read any Self-Test codes in this mode.
Key On Engine Running (KOER) SelfTest

1. Start and warm up the engine until it is at a normal running temperature.
2.. Turn the engine off.
3. Depress the test button to the test position, then restart the engine.
The tester will now display an engine I.D. code, and on certain vehicles, a Dynamic Response
code. Then, service codes will be displayed.

ALL RIGHTS RESERVED
14-32 EECIV Quick Test Procedures and Appendix

SUPER STAR II Tester
For a detailed description of the variety of tests that can be run with the SUPER STAR II,
refer to the instruction manual provided with the tester.
SLOW/FAST
READOUT SWITCH
MEM/REV
BUTlON A12791A
Figure 5 SUPER STAR /I Tester

ALL RIGHTS RESERVED
EEC-IVQuick Test Procedures and Appendix 14-33

Analog Voltmeter
READING CODES - ANALOG VOLTMETER
When a service code is reported on the analog voltmeter for a function test, it will represent
itself as a pulsing or sweeping movement of the voltmeter's needle across the dial face of the
voltmeter (Figure 6). Therefore, a single-digit number of three will be reported by three needle
pulses (sweeps). However, as previously stated, a service code is represented by a two-digit
number, such as 2-3. As a result, the Self-Tests service code of 2-3 will appear on the
voltmeter as two needle pulses (sweeps), then, after a two-second pause, the needle will
pulse (sweep) three times.
The Continuous Memory Codes are separated from the Key On Engine Off codes by a six-
second delay, a single half-second sweep, and another six-second delay. They are produced
on the voltmeter in the same manner as the Key On Engine Off codes.
2 NEEDLE PULSES
+ 1 NEEDLE PULSE (SWEEP) .=
1\
1 NEEDLE PULSE (SWEEP) (SWEEPS) FOR
1ST DIGIT
12.SECOND PAUSE BETWEEN DIGITS
L~I _,
~ SERVICE
CODE
1 NEEDLE PULSE 1 NEEDLE PULSE 1 NEEDLE PULSE 3 NEEDLE PULSES

(SWEEP) + (SWEEP) + (SWEEP) = (SWEEPS) FOR
2ND DIGIT
FOR 1/2 SECOND FOR 1/2 SECOND FOR 1/2 SECOND
4-SECOND PAUSE BETWEEN SERVICE CODES,

WHEN MORE THAN ONE CODE IS INDICATED
A820S-C
Figure,6 Analog Voltmeter Output Code Format

ALL RIGHTS RESERVED
14..34 EEC-IV Quick Test Procedures and Appendix
APPENDIX: Self-Test With "CHECK ENGINE"

or "SERVICE ENGINE SOON"
Light (MIL)
READING' CODES - "CHECK ENGINE" or "SERVICE ENGINE SOON" LIGHT (MIL)
During Self-Test a service code is reported by the "CHECK ENGINE" or "SERVICE ENGINE
SOON" Light. It will represent itself as a flash on the "CHECK ENGINE" or "SERVICE
ENGINE SOON" Light display on the dash panel (Figure 7). A single-digit number of three will
be reported' by three flashes.
However, as p'reviously stated, a service code is represented by a two-digit number, such as

2-3. As a result, the Self-Test service code of 2-3 will appear on the "CHECK' ENGINE" or
"SERVICE ENGINE SOON" Light display as two flashes, then, after a two-second pause, the
light will flash three times.
The Continuous Memory Codes are separated from the Key On Engine Off codes by a six-
second delay, a single half-second flash, and another six-second delay. They are produced on
the "CHECK ENGINE" or "SERVICE ENGINE SOON" Light display in the same manner as
the Key On Engine Off codes.
"CHECK "CHECK
1/2
ENGINE" ENGINE"
I--SECOND-
OR "SERVICE OR "SERVICE
PAUSE
ENGINE SOON" ENGINE SOON"
1 FLASH + 1 FLASH = 2 FLASHES FOR

1ST DIGIT
I 2-SECOND PAUSE BETWEEN DIGITS
~
.. 1,.- 1-'-, SERVICE
CODE
"CHECK "CHECK "CHECK

ENGINE" 1/2 1/2 ENGINE"
ENGINE"
-SECOND- --SECONo-
OR "SERVICE OR "SERVICE OR "SERVICE
PAUSE PAUSE
ENGINE SOON" ENGINE SOON" ENGINE SOON"
1 FLASH + 1 FLASH + 1 FLASH = 3 FLASHES FOR

FOR 1/2 SECOND FOR 1/2 SECOND FOR 1/2 SECOND 2ND DIGIT
1
I 4SECOND PAUSE BETWEEN SERVICE CODES,
WHEN MORE THAN ONE CODE IS INDICATED
A 11517B
Figure 7 "CHECK ENGINE" or "SERVICE ENGINE SOON" Light Output Code Format

ALL RIGHTS RESERVED
EECIV ..Quick Test Procedures and Appendix 1435

Message Center (Continental Only)
HOW TO RUN SELF-TEST USING THE CONTINENTAL MESSAGE CENTER

1. On the Electronic Instrument Cluster, hold in all three buttons (SELECT, RESET and
SYSTEM CHECK) at the same time.
2a. Key On Engine Off Self-Test
While holding in all three buttons, place ignition switch in the ON position. Release
buttons.
3. Engine Running Self-Test
While holding in all three buttons, start engine. Release buttons.
4. Press the SELECT button three times.
5. To initiate Self-Test, jumper STI to SIG RTN at the Self-Test connectors, or use a STAR
Tester and latch the center button in the down position.
- Key On Engine Off
A base readout of 4255 indicates that Self-Test has been entered successfully.
- Engine Running
A base readout of 4030 indicates the engine 10 code (one-half the number of engine
cylinders, Le., 30 + 6 cylinders) and that Self-Test has been entered successfully.
6. Service code output will be the right three digits displayed (e.g. PASS code readout:
4011 ).
7. To exit Self-Test, turn ignition switch to OFF and remove jumper or unlatch STAR Tester.
MESSAGE DISPLAY
._.,.-,
11.-"
..
,
INST AVG TRIP /ISELECTI]
ECON ECON DTE DIST
CHECK
ENGINE
[8
SYSTEM
CHECK
A12792-A
Figure 8 Message Center in Self-Test Mode

ALL RIGHTS RESERVED
1436 EECIV Quick. Test Procedures and Appendix
APPENDIX: Self-Test With Overdrive

Cancel/Transmission Malfunction
Indicator Light - OCIL/TMIL
READING CODES - OVERDRIVE CANCEL/TRANSMISSION MALFUNCTION

INDICATOR LIGHT (OCIL/TMIL)
The OCIL/TMIL serves a dual purpose on the 7.3L Diesel vehicle with E40D transmissions.
The light stays OFF when the Overdrive Cancel Switch (OSC) is toggled once on the
instrument panel - indicating that the vehicle can attain the overdrive gear position.
The light stays ON when the Overdrive Cancel Switch (OSC) is toggled again on the
instrument panel - indicating that the vehicle is prevented from shifting into the overdrive
gear position.
If the light flashes, then perform Key On Engine Off Self-Test. A code 99 indicates a fault
in the E40D Transmission Electronic Pressure Control (EPC) circuit. The light under this
condition' serves as the Transmission Malfunction Indicator Light (TMIL).

ALL RIGHTS RESERVED
APPENDIX: Diagnostic Aids
CONTINUOUS MONITOR MODE (WIGGLE TEST)
SPECIAL NOTE:
The Continuous Monitor Modes allow the technician to
ATTEMPT to re-create an intermittent fault.
KEY ON ENGINE OFF WIGGLE TEST PROCEDURE

1. Hook up a STAR Tester or YOM as shown in Quick Test Step 12.0 1.
2. Turn the ignition key to the ON position.
3. Activate, wait 10 seconds, deactivate and reactivate Self-Test.
4. You are now in the Continuous Monitor Mode.
5. Tap, move, and wiggle the suspect sensor and/or harness. When a fault is detected, a
Continuous Memory Code will be stored in memory. This will be indicated as follows
depending on the type of equipment being used:
STAR Tester: Red LED lights and/or continuous tone.
"CHECK ENGINE" or "SERVICE ENGINE SOON" Light: Lights
YOM: Needle Sweep
ENGINE RUNNING WIGGLE TEST PROCEDURE

1. Hook up a STAR Tester or YOM as shown in Quick Test Step 12.0 I.
2. Key off, wait 10 seconds.
3. Start the engine.
4. Activate Self-Test, wait 10 seconds, deactivate and reactivate Self-Test. DO NOT shut the
engine off.
5. You are now in the Engine Running Continuoys Monitor Mode.
6. Tap, move, and wiggle the suspect sensor and/or harness. When a fault is detected, a
Continuous Memory Code will be stored in memory. This will be indicated as follows .
depending on the type of equipment being used:
STAR Tester: Red LED lights and/or continuous tone.
"Check Engine' or "SERVICE ENGINE SOON' Light (MIL): Lights
YOM: Needle Sweep

ALL RIGHTS RESERVED
HOW TO CLEAR THE CONTINUOUS MEMORY CODES

NOTE: Do not disconnect battery to clear Continuous Memory Codes. This will erase the
Keep Alive Memory (KAM) information which may cause a driveability concern.
1. Run the Key On Engine Off Self-Test according to Quick Test Step 13.0 1.
2. When the Service Codes begin to be displayed, deactivate Self-Test:
- STAR Tester: Unlatching the center button (up position).
- Analog YOM: Remove the jumper wire from between Self-Test Input (STI) connector
and the Signal Return Pin of the Self-Test connector.
- "CHECK ENGINE" or "SERVICE ENGINE SOON" Light (MIL): Remove the jumper
wire from between Self-Test Input (STI) connector and the SIGNAL
RETURN pin of the Self-Test connector.
- Message Center (Continental Only): Remove the jumper wire from between Self-Test
input (STI) connector and the SIGNAL RETURN pin of the Self-Test
connector.
3. The Continuous Memory codes will be erased from the processor's memory.
HOW TO CLEAR KEEP ALIVE MEMORY (KAM)

The processor stores information about vehicle operating conditions and uses this information
to compensate for component tolerances. When EGR, HEGO, INJECTORS, MAP/BP, TPS or
VAF are replaced, Keep Alive Memory (KAM) should be cleared to erase the information
stored by the processor from the original component.
To clear KAM: Disconnect the negative side of the battery for a minimum of five minutes.
After KAM has been cleared, the vehicle may exhibit certain driveabifity concerns. It will be
necessary to drive the vehicle 10 miles or more to allow the processor to relearn values for
optimum driveability and performance. (Distance is dependent on the vehicle application.)
OUTPUT STATE CHECK

The output state check aids in servicing output actuators associated with the EEC-IV system. It
enables the technician to energize and de-energize most of the system output actuators on
command. This mode is entered after all codes have been received from Key On Engine. Off
and Continuous Testing. At this time, leave Self-Test activated and depress the throttle. Each
time the throttle is depressed the output actuators will change state from energized to de-
energized or from de-energized to energized.
1. Enter Self-Test.
2. Code Output Ends.
3. Do Brief WOT.
4. ~EC-IV Output To Actuators Energized.
5. Do Brief WOT.
6. EEC-IV Output To Actuators De-Energized.

ALL RIGHTS RESERVED
I APPENDIX: Diagnostic Aids
CYLINDER BALANCE TEST - SEFI ENGINES
The purpose of the cylinder balance test is to assist the mechanic in' finding a weak or non-
contributing cylinder. The test is entered by depressing and releasing the throttle within two
minutes after the Engine Running Self-Test code~ have been output. .
. ' .\ . '. .'
Once the test is entered, the idle speed control duty is fixed and the engine is allowed to
stabilize. Engine rpm is measured and stored for later use; Next, th~ fuel is shut off to
cylinder number 4, 6 or 8, depending on engine. After a brief stabilization period the engine
:rpm is again measured and stored. The injector"is turned on' again al')d the process is
repeated for each of the injectors down to one; At this point, the maximum rpm drop that
occurred is selected frqm the table of rpm drops for each cylinder. This maximum rpm drop is
now multiplied by a calibratable percentage. Th~ resulting numbe~ (rpm) is' now used as the'
minimum rpm that each cylinder must have dropped to pass this test. .
Example: 1,50, rpm x 65% = 98 rpm
If -all cylinders drop at least this amount, then a cod'e 90 is outpu( indicating a pass. No
further testing 'is necessary. 'If a cylinder did nof drop at least this amount, then the cylinder
number would be output. For example, 30 for cylinder number 3. Thi~ indicates that cylinder
number 3is either weak or non-contributing. .
The test can now be repeated a second time if the throttle is depressed and. released within
two minutes of the last code output. This time the maximum rpm drop that occurs is multiplied
by a lower percentage. This number is now used as the minimum rpm drop for each cylinder
to pass this test.
Example: 150 rpm x 43% = 65 rpm

If all the rpm drops are greater than 65 rpm, then a code 90 is output. If cylinder number 3
had failed the first level and passed the second, then cylinder number 3 is considered to be
weak. If cylinder number 3 again failed, the code 30 would be output again.
The test can be repeated a third time by depressing and releasing the throttle within two
minutes of the last code output. This time the maximum rpm drop that results is multiplied by
a still lower percentage. This number is now used as the minimum rpm drop for eac~ cylinder
to pass this test.
Example: 150 rpm x 20% = 30 rpm
If all the rpm drops are greater than 30 rpm then a code 90 is output. If cylinder number 3
had failed the first and second level, but passed the third, then it is considered to be a very
weak cylinder. If cylinder number 3 failed the third level then a code 30 would again be
output. In this case, cylinder .number three would be considered a non-contributing cylinder.
"
(Continued)

ALL RIGHTS RESERVED
"APPENDIX: Diagnostic Aids"
The Cylinder Balance Test may still be repeated as many times as desired by depressing and
releasing the throttle within two minutes of the last code output. All further testing (Le. 4th, 5th
pass) will be done using the third level percentage.
POSSIBLE CODE OUTPUTS (code 30 Is used as an example only)
x = no further testing necessary
LEVEL
1 2 3" INDICATION POSSIBLE EEC CAUSES
Indicates a pass, all cylinders
90 X X
contributing equally.
30 90 X Indicates a weak cylinder. Partially clogged injector
Cylinder is firing, but not Injector/harness resistance
contributing as much as the others. out of specification
30 30 90 Same as above, but more severe. Same as above, but more severe
30 30 30 Very weak or dead cylinder. Open or shorted circuit
Loss of injector drive signal
Fully clogged injector

ALL RIGHTS RESERVED
FAILURE MODE EFFECTS MANAGEMENT (FMEM)
FMEM is an alternate system strategy in the ECA designed to allow improved vehicle drive
should one or more sensor inputs fail.
When a sensor input is perceived to be out-of-limits by the ECA, an alternative strategy will be
initiated.
. The ECA will substitute a fixed in-limit sensor value and will continue to monitor the faulty
sensor input. If the faulty sensor operates within limits, the ECA will return to the normal
engine running strategy.
Engine Running Service Code 98 will be displayed when FMEM is in effect. .
The "CHECK ENGINE" or "SERVICE ENGINE SOON" Light (MIL)/Message will remain on
when FMEM is in effect.

ALL RIGHTS RESERVED
"CHECK ENGINE" OR "SERVICE ENGINE SOON" LIGHT (MALFUNCTION

INDICATOR LIGHT) ALL APPLICATIONS EXCEPT CONTINENTAL
The "CHECK ENGINE" or "SERVICE ENGINE SOON" light is intended to alert the driver of
certain malfunctions in the EEC-IV system. If the light is on, the driver of the vehicle should
take the car in for service as soon as possible.
NOTE: It is not necessary to Immediately turn the engine off and have the vehicle
towed when the "CHECK ENGINE" or "SERVICE ENGINE SOON" light comes on.
The "CHECK ENGINE" or "SERVICE ENGINE SOON" light will come on while the engine is
operating in Failure Mode Effects Management (FMEM) or Hardware Limited Operation Strategy
(HLOS) modes. The light will stay on as long as the fault causing it is present.
In FMEM mode, the processor is receiving a sensor signal that is outside the limits set by the
calibration strategy. In this mode the processor uses an alternate engine control strategy to
maintain reasonable vehicle operation in spite of the fault. Following is a list of system faults
which will turn on the "CHECK ENGINE" or "SERVICE ENGINE SOON" light in this mode.
The error code associated with this fault is stored in Keep Alive Memory (KAM). If the fault is
no longer present, the light will turn off and the vehicle will return to the normal vehicle
strategy. The error code stored when the light was on is not erased. This code is one of the
Continuous Memory codes, and it can be accessed by running the Key On Engine Off Self-
Test.
HLOS mode is used when the system fault(s) is too extreme for the FMEM mode to handle.
In HLOS mode, all software operations have stopped and the processor is running on
hardware control only. The default strategy for this mode has a minimal calibration strictly to
allow the vehicle to operate until it can be serviced.
NOTE: In HLOS mode Self-Test codes will not be output.

ALL RIGHTS RESERVED
HOW THE "CHECK ENGINE" OR "SERVICE ENGINE SOON" LIGHT OPERATES

System OK
The "CHECK ENGINE" or "SERVICE ENGINE SOON" light is turned on as a bulb check
when the ignition key is first turned on. The EEC-IV processor turns the bulb off as soon as it
receives the PIP (cranking) signal.
System Not OK
If the "CHECK ENGINE" or "SERVICE ENGINE SOON" light should remain on after the
vehicle has started, run Quick Test and service any codes. If Self-Test has pass codes, the
"CHECK ENGINE" or "SERVICE ENGINE SOON" or light is always on and the vehicle has
no drive symptoms, go to Quick Test Step 9.0.
If the "CHECK ENGINE" or "SERVICE ENGINE SOON" light never comes on, go to Quick
Test Step 19.0 I.
. .
If the vehicle is a no start, go to Pinpoint Test Step IA 1 I.
The following can activate the "CHECK ENGINE" or "SERVICE ENGINE SOON" light:
Continuous
"CHECK EN~INE" or "SERVICE ENGINE SOON" Light System Fault(s)
Memory Codes
ECT Engine Coolant Temperature 51, 61

ACT Air Charge Temperature 54,64
BP Barometric Pressure 22
MAP Manifold Absolute Pressure 22
VAF Vane Air Flow 56,66
MAF Mass Air Flow 56,66
EGO, HEGO Exhaust Gas O2 41, 42, 91
PFE Pressure Feedback EGR 31, 35, 33*
EVP EGR Valve Position 31, 35, 33*
TP Throttle Position 53,63
ITS Idle Tracking Switch 71
10M (DPDIS) Ignition Diagnostic Monitor 18, 28, 48, 88
10M (DIS) Ignition Diagnostic Monitor 45, 46, 48
VAT Vane Air Temperature 58,68
If D.C. motor does not follow dashpot profile 13
* 1990 1/2 5.0L Truck Only
NOTE: When in Self-Test the "CHECK ENGINE" or "SERVICE ENGINE SOON" light is
not limited to Continuous Memory Codes and will also flash the service codes.

ALL RIGHTS RESERVED
"CHECK ENGINE"I"CHECK DCl" MESSAGE (DATA COMMUNICATIONS LINK)
Continental Applications Only
The EEC-IV processor transmits the "CHECK ENGINE" message to the message center
through the Data Communications Link (DCl). The message center is used to display the
"CHECK ENGINE" and/or "CHECK DCl" messages.
HOW THE "CHECK ENGINE" MESSAGE OPERATES
Service Codes: Service codes can be digitally displayed on the message center when running
Self-Test. (See Appendix: Self-Test)
The "CHECK ENGINE" message is activated when the EEC-IV processor switches to an
alternate strategy of operation. This process is called Failure Mode Effects Management
(FMEM). The "CHECK ENGINE" message is intended to alert the driver of certain
malfunctions in the engine control system.
FMEM Mode: The "CHECK ENGINE" message is displayed and accompanied by a one
second tone every five seconds. The tone is suppressed after one minute.
The "CHECK ENGINE" message will also be activated during an EEC-IV processor Hardware
Limited Operating Strategy (HlOS) mode.
HLOS/DCL Failure: The "CHECK ENGINE" message will be displayed as described in FMEM.
In addition, the message "CHECK DCl" will also be displayed.
If the "CHECK ENGINE" and/or "CHECK DCl" message should come on after the vehicle
has started, RUN Key On Engine Off Self-Test to completion. If the message continues to
remain on, go to Quick Test Step 19.0 I.
If the vehicle is a no start, go to Pinpoint Test Step IA 1 I.

ALL RIGHTS RESERVED
EEC~IV Quick Test Procedures and- Appendix 1445
APPENDIX: Test Equipment

I
EQUIPMENT REQUIRED:
Self-Test Automatic Readout- (STAR), Rotunda No. 007-00004 with cable assembly No. 007-
00010. Refer to STAR Tester operation.
Analog volt-ohmmeter, 0 to 20V DC, (alternate to STAR).
DtAL FACE
I.'a:-I.:Q
/lIotu11da_1 - _10. ~N'
V$!FQ'
~on I
~u~~
"."'00"'''
.110<13
~$
~'~
_
,-
01
eeL_ 'feeT .&uTCHIlIIA"tC
AUTOMATIC READOUT (STAR) TESTER ANALOGVOLTUETER

A1151.A A11521-A
Jumper wire.
Vacuum -gauge, Rotunda 059-00008 or equivalent. Range 0-30 in-Hg. Resolution 1 in-Hg.
JUMPER WIRE
A11520-A

ALL RIGHTS RESERVED
APPENDIX: Test Equipment (Continued)
Tachometer, Rotunda No. 059-00010 or equivalent. Range 0-6,000 rpm. Accuracy 40 rpm.
Resolution 20 rpm.
Breakout Box, Rotunda 014-00322, Special Service Tool T83L-50-EEC-IV or equivalent.
BREAKOUT SOX
A11525-A
TACHOMETER
A11523-A
Vacuum pump, Rotunda No. 021-00014 or equivalent. Range 0-30 in-Hg.
Digital volt-ohmmeter, Rotunda No. 014-00407 or equivalent. Input impedance 10 Megaohm

minimum.
.:. -.
DIGITAL VOLT-OHMMETER
VACUUM PUMP A11526-A
A11524-A

ALL RIGHTS RESERVED
OPTIONAL EQUIPMENT
SUPER Self-Test Automatic Readout II, (SUPER STAR II), Rotunda No. 007-00028.
EEC~IV Monitor Box, Rotunda No. 007~00018.
SUPERSTAR II
A12793A EECIV MONITOR BOX A12794A
EEC~IV Monitor Recorder, Rotunda No. 007-00021.
Integrated Relay Controller Module (IRCM) Tester, Rotunda No. 007~00050.
r~.-"I
1\
:
17.:
I
.
INTEGRATED RELAY CONTROLLER

EEe-IV MONITOR RECORDER A12795-A MODULE TESTER A13592-A

ALL RIGHTS RESERVED
1448 EEC-IV Quick Test Procedures and Appendix
Electronic Fuel Injection Pressure Gauge EFI/CFI only, Tool T80L-9974-A or equivalent. (Use
instructions. For specific applications, refer to Fuel/Engine Shop Manual Group)
Spark tester (optional modified spark plug with side electrode removed). Tool D81 P-6666-A
or equivalent.
SPARK TESTER
EFI PRESSURE GAUGE A11529-A
A11527-A
Timing light, Rotunda model 059-00006 or equivalent.

Non-powered test lamp.
N()N.ft()WERED TEST-LAMP
A115A
TIllING LIGHT
Al1U.A

ALL RIGHTS RESERVED
SECTION 15
EEC-IV-Engine Supplement-
Passenger Car
Contents
Diagnostic SensorlActuator Reference Values-
Passenger Car 15-1
1.9 EFI
Electrical Schematic 15-3
EEC-IV Module Connector Pin Usage 15-4
Quick Test Codes and Code Definitions : 15-5
1.9L CFI .
Quick Test Codes and Code Definitions 15-8
1.9L MA SEFI
Electrical Schematic ................................................................ 15-9
Quick Test Codes and Definitions 15-12
2.3L OHC EFI
Electrical Schematic............................................................... 15-13
Quick Test Codes and Code Definitions ; 15-15
2.3L MA EFI
2.3L HSC EFI
EEC-IV Module Connector Pin Usage ~ 15-20
(Continued)

ALL RIGHTS RESERVED
SECfION 15
EEC-IV-Engine Supplement-
Passenger Car
Contents
2.5L F~C CFI
EEC-IV Module Connector Pin Usage '.' 15-23
Integrated Controller Schematic 15-25
Integrated Controller Pin Usage 15-26
2.9L EFI
3.0L EFI
3.0L SHO SEFI
Quick Test Codes and C<;>de Definitions 15-46
3.8L AXOD SEFI
(Continued)

ALL RIGHTS RESERVED
SECTION 15
EEC-IV~Engine Supplement-
Passenger Car
Contents
3.8L RWD SEFI
Electrical Schematic ; 15-55
3.8L SC SEFI
5.0L SEFII5.0L MA SEFI
Electrical Schematic :...................................... 15-66
. EEC-IV Module Connector Pin Usage 15-70

ALL RIGHTS RESERVED
EECIV - Engine Supplement - Passenger Car 15-1
Diagnostic' Sensor/ Actu~tor Reference Values .Car
NOTES: .
The chart below contains typical component values.
Values measured in the field may differ slightly from those shown.
Do not compare reference values found on this chart with monitor-box data. Monitor-box data is measured with
respect to a different reference level in some cases.
Breakout box pin number assignments differ from vehicle to vehicle. Refer to the Pin Usage Chart applicable to the
vehicle being serviced for the correct pin assignments.
Each vehicle application will not have all components listed below.
Pre-condition the engine in the following manner ,before recording any values:
- The' engine should be at a normal operati~g condition.
- Start and run engine at 2000 rpm for two minutes.
Breakout Key Off

Box Pin Throttle Key On Hot
Numbers Closed Eng. Off Idle
INPUTS (+) (-) (ohms) (volts) (volts)
* Clutch Engage Switch (CES) CD 30 40. - - -
Coil Tach Signal (10M) 4 16 21.8 K 8.0 to 10.0 8.0 to 12.0
* Distributor Position (PI P) 56 16 1.1 K to 2.1 .K - 3.0 to 7.0
EGR Valve Position (EVP) 27 46 480 to 650 0.30 to 0.45 0.30 to 0.45
* Engine Coolant Temperature (ECT) 7 46 1.7 K to 3.6 K - 0.31 to 1.0
(Heated) Exhaust Gas Oxygen (H)EGO 29 46 >1.5 M <0.4 0.0 to 0.9
* Knock Sensor (KS) @ 23 46 4.5 K to 6.5 K -
* Manifold Pressure (MAP) 45 46 - - -
Barometric Pressure (BP)
* Mass Air Flow (MAF) 50 . 40 - - -
* Neutral/Drive Switch (NOS) CD 30 ' 40 - - -
* Power Steering Pressure Switch 24 46 - - -
(PSPS)
Pressure Feedback EGR (PFE) 27 46 - 3.0 to 3.5 3.0 to 3.5
Reference Voltage (VREF) 26 46 - 5.05% 5.05%
Throttle Position (TP) 47 46 0.5 K to 1.2 K 0.7 to 1.3 0.7 to 1.3
* Vehicle Speed Sensor (VSS) 3 6 190.0 to 240.0 - -
OUTPUTS
* Canister Purge (CANP) @ 37 31 60.0 to 70.0 0.0 0.0
Computed Spark Advance (DIS) 36 16 - 9.0 to 12.5 8.5 to 9.5
Computed Spark Advance (TFI) 36 16 - 0.0 5.0 to 7.0
Spark Angle Word (SAW) 36 16 - - 0.5 to 0.7
EGR Valve Regulator (EVR) 37 33 40.0 to 50.0 0.0 (OFF) 0.0 (OFF)
Fuel Pump Relay (FP) 37 22 - 0.0 (OFF) VBAT (ON)
* Idle Speed By Pass (IBA) 37 21 9.5 to 11.5 0.0 (OFF) 2.0 to 5.5
* Injectors Bank # 1 ([j) 37 58 - 0.0 -
* Injectors Bank # 2 <D> 37 59 - 0.0 -
* Numbers to the right of .these Inputs/outputs refer to explanations on next page.

ALL RIGHTS RESERVED
152 EECIV - Engine Supplement - Passenger Car
Diagnostic Sensor/Actuator Reference Values Car
Explanations -
CD If the clutch pedal is down, the switch is closed.

If the clutch pedal is up, the switch is open.
@ For applications containing TFI-IV systems only.
Engine coolant temperature must be within the 180-240F (82-116C) temperature range
before measurements are taken.
@ The Knock Sensor output voltage is a variable signal of 300 mV or greater, depending on
the severity of engine knock; background noise is not part of the sensor output.
@ Refer to the Altitude vs. Voltage Chart in Pinpoint Test OF, Section 17 for proper
operating values.
@ Refer to the MAF Sensor Data Chart in Pinpoint Test DC for proper operating valves.
(/) The NOS is open in any gear, but closed in. neutral or park.
If power steering pressure rises above a specified limit, the switch contacts will open and
the ECA will adjust idle speed to compensate for the extra load placed on the engine.
If vehicle is not moving, the speed sensor output to the processor will be zero. The
v~hicle must be moving for the speed sensor to provide information to the processor.
@) Not all applications will use Pin 31 for canister purge. Refer to appropriate Vehicle Pin
Usage Chart.
@ Refer to the Injector Resistance Chart in Pinpoint Test H, Section 17 for the proper
resistance values.

ALL RIGHTS RESERVED
"'"'0
MfT
~ CLUTCH H~'<U <~'N< 'H~' 'c< ~UM<OH~ ~H<
...rn
~
<
I
EN A
SW~T;HE
I EXHAUST GAS COOLANT POSITION PRESSURE AIR FLOW
a... "'
.~
HEGO OXYGEN SENSOR TEMPERATURE SENSOR SENSOR METER SELFTEST ~
GROUND (HEGO) (ECT) (TP) (BP) (VAFNAT) CONNECTOR ' co
1 ~WJr
S
~UT~L V ~ , ...
CD
'GEAR . r-
~
-- .
0 ~I~"
SEll TEST n en
46
SWITCH
49. 7 II'
>-
~ 46 25
- - - UT
(:
I) I c
"0
29 46 'LIT 45 43 ov "0
POWER TO 26 26 46 17 If (I) CD
3
. GND 46 46
~ n
-I
CD
I _ IGNITION 26 SHFT
P . 22
cr,
I .
I NGS & CES
I HF=r.OG
RUN 47 NDICATOR ~ ~
~
a
6O-PIN I HEGO LIGHT ,
,ECT
20 40 60 "U
, TP m
i BP
VAT
TO
IGNITION
SWITCH
....
1' (I)
(I)
CD
I VAF
n ~
co
, VREF
,SIG RTN ...
CD
r STO 0
I STI
10M 22K "lU."
INJECTORS
...
m
2 3
, TO IGNITION
COIL(-)
1 21 41
IDLE
SPEED
CONTROL EGR
BYPASS SHUT.QFF TO
AIR (EGR SlO) CANISTER FUEL 4 I. ,
(ISC-BPA) PURGE PUMP
i!il
SOLENOID (CANP
pgrup
~~
1
~
~ ~
eWR GNp 60
/ ~BATT+
CYCLIC AlC OEM. .
PRESSURE SWITCH TO
SWITCH IGNITION 4 '
SWITCH
rn'~
ALL RIGHTS RESERVED
NOTE: WIRING SCHEMATIC SHOWS PIN OUT LOOKING INTO HARNESS CONNECTORS A894SE --n\C
.... r- ~
en

Cot)
1.9L
EEC-IV Module Connector Pin Usage
EFI
Pin Circuit Wire Color Application Abbreviations

1 37 Y Keep Alive Power KAPWR
4 11 DG/Y Ignition Diagnostic Monitor 10M
7 354 LG/Y Engine Coolant Temperature ECT
8 787 PK/BK Fuel Pump Monitor FPM
10 347 BK/Y A/C Clutch Compressor ACC
16 259 BK/O Ignition Ground IGN GND
17 224 T/LB Self-Test Output and Shift Indicator Light STO and SIL
20 57 BK Case Ground CSE GND
21 68 O/BK Idle Speed Control (Bypass Air) ISC-BPA
22 97 T/LG Fuel Pump FP
25 357 LG/P Vane Air Temperature VAT
26 351 O/W Reference Voltage VREF
29 94 DG/P Heated Exhaust Gas Oxygen Sensor HEGO
30 614 GY/O Neutral Drive Gear Switch and Clutch Engage Switch NOS and CES
32 101 GY/Y Canister Purge Solenoid CANP
35 362 Y Exhaust Gas Recirculation Shut Off EGR S/O
36 324 Y/LG Spark Output SPOUT
37 361 R Vehicle Power VPWR
40 60 BK/LG Power Ground PWR GND
43 200 W/BK Vane Air Flow . VAF
45 358 LG/BK Barometric Pressure BP
46 359 BK/W Signal Return SIG RTN
47 355 DG/LG Throttle Position Sensor TP
48 100 W/R Self-Test Input STI
49 89 0 Heated Exhaust Gas Oxygen Ground HEGOG
53 201 T/R "CHECK ENGINE" Light MIL
54 73 O/LB Wide Open Throttle AIC Cut-Off WAC
56 349 DB Profile Ignition Pickup PIP
58 95 T/R Injector Bank 1 INJ Bank 1
59 96 TIO Injector Bank 2 INJ Bank 2
Pin locations given for reference only. Probing 60 pin

connector with DVOM probe will result in permanent damage
-
'Of00000000005! 500000000000
- 41
to the pin connectors. Always probe as directed, using the 40 000000000031@300000000000 21
Breakout Box. 20 0000000000" 100000000000 1

ALL RIGHTS RESERVED
EECIV - Engine Supplement - Passenger Car 155
1.9L
Quick Test Codes andC~de Definitions
EFI
SERVICE CODE SERVICE CODE DEFINITION
11 orc ~ System PASS
12 r ~ RPM unable to achieve Self-Test upper limit
13 r ~ RPM unable to achieve Self-Test lower limit
14 c ~ PIP circuit failure
15 0 ~ ECA Read Only Memory (ROM) test failed
15 c ~ ECA Keep Alive Memory (KAM) test failed
16 r ~ Idle rpm high with ISC off
17 r ~ Idle rpm low with ISC C?ff ,.
18 r ~ SPOUT circuit open
18 c ~ 10M circuit failure/SPOUT circuit grounded
19 r ~ Rpm dropped too low during ISC off test
21 or ~ ECT out of Self-Test range'
22 orc ~ BP out of Self-Test range
23 or ~ TP out of Self-Test range
26 or ~ VAF out of Self-Test range
28 or ~ VAT out of Self-Test range
41 r ~ HEGO sensor circuit indicates system lean
41 c ~ No HEGO switch detected - indicates lean
42 r ~ HEGO sensor circuit indicates system rich
42 c ~ No HEGO switch detected - indicates rich
43 c ~ HEGO lean at wide open throttle
47 r ~ Measured airflow low at base idle
48 r ~ Measured airflow high at base idle
51 oc ~ ECT indicated - 40F/circuit open
53 oc ~ TP circuit above maximum voltage
56 oc ~ VAF circuit above maximum voltage
58 oc ~ VAT indicated - 40F/ circuit open
61 oc ~ ECT indicated 254F/circuit grounded
63 oc ~ TP circuit below minimum voltage
65 c ~ Never went to closed loop fuel
66 oc ~ VAF circuit below minimum voltage
67 d ~ Neutral Drive Switch (NOS) circuit open/A/C on
67 c ~ Clutch switch circuit failure
68 . oc ~ VAT indicated 254F/circuit grounded
71 c ~ Software reinitialization detected
72 c ~ Power interrupt/reinitialization detected
73 r ~ Insufficient TP change during Dynamic Response Test
76 r ~ Insufficient VAF change during Dynamic Response Test
77 r ~ Brief WOT not sensed during Self-Test/Operator error
85 c ~ Adaptive fuel lean limit reached
86 c ~ Adaptive fuel rich limit reached
95 oc ~ Fu.el pump secondary circuit failure
96 oc ~ Fuel pump secondary circuit failure
NO CODES ~ Unable to initiate Self-Test or unable to output Self-Test codes
CODES NOT LISTED ~ Service codes displayed are not applicable to the vehicle being tested
KEY: 0 = Key On Engine Off (KOEO) r = Engine Running (ER) c = Continuo~s Memory

ALL RIGHTS RESERVED
~
U'I
I
en
IGN. START
SWITCH
NEUTRAL
DRIVE SWITCH
HEATED
EXHAUST GAS
OXYGEN
ENGINE
COOLANT
THROTILE
j
POSITION
TEMPERATURE SENSOR
AIR
CHARGE
TEMPERATURE
MANIFOLD
ABSOLUTE
PRESSURE
PRESSURE
FEEDBACK
EGR (PFE) ...m
~:ONLI
HEGO
GROUND
STARTER
~
SENSOR
E11tW
(HEGO)
0
SENSOR
(ECT)
(TP)
,I I,
SENSOR
(ACT)
SENSOR
(MAP)
,i
SELFTEST
CONNECTOR
SELF-TEST
a....
~
J
...
n
INPUT
30 :: RELAY POWER ~
HEGOG - GND 29 7 47-
I
(STI)
49
C
29
7
HEGO
ECT
I 146
I
126 46 27 26
D~
47
TP
"CHECK
ENGINE" 17
rn
25
A'::.l
MAP
LIGHT I 48
g.
f
45
PFE
27
60-PIN \lREF ~
a
26
20 40 60
51 SIL ~ TO SHIFT INDICATOR LAMP CIRCUIT (MIT ONLY)
SIG RTN T O IGN.
46
17
48
STO/MIL
STI
RUN
........
C
4 10M 22~MS I TO IGNITION ~ IG~~~ON n
56 PIP ; - - - - - - --- COIL CIRCUIT INJECTOR
SPOUT ,\ , ONLY
(~
36
IGN GND ' I
16
CASE GND -----------
20
37/57 58
22
INJ J
58
CANP
35
52
EVR
I
35
37
~WR I
J 4~ rn
57 VPWR rn
28
21
II~~(+)
ISC(-)
~
_(
I oI
:<
41
1 21 41
I
rn
~
8 co
1
S
CD
40
60 tJ)
C
5 ~
10 ~
54 CD
3
..I
, 5_
CD
TO ~
IGNITION~
SWITCH
I
AlC
CLUTCH "'U
D)
0)
-:
ALL RIGHTS RESERVED
n~
NOTE: WIRING SCHEMATIC SHOWS PIN OUT LOOKING INTO HARNESS CONNECTOR A8479-D
~\C
.... r-- =
::J
co
...
CD
o
...
D)
EEC-IV - Engine Supplement - Passenger Car 15-7
1.9L
CFI
5 16 R/LG Key Power KPWR
7 354 LG/Y Engine Coolant Temperature Sensor ECT
17 201 T/R Self-Test Output/"CHECK ENGINE" Light STO/MIL
21 376 BR/W Idle Speed Control (DC Motor) ISC (+)
22 97 - T/LG Fuel Pump Relay FP
25 357 LG/P Air Charge Temperature Sensor ACT
27 352 BR/LG Pressure Feedback EGR PFE
28 265 LG/W Idle Tracking Switch ITS
29 94 DG/P Heated Exhaust Gas Oxygen Sensor . HEGO
30 614 GY/O Neutral Drive Switch .(A/T Only) NOS
35 101 GY/Y Canister Pyrge Solenoid CANP
41 264 - W/LB Idle Speed Control (DC Motor) ISC (-)
45 358 LG/BK Manifold Absolute Pressure Sensor MAP
46 ~59 BK/W Signal Return (Ground) SIG RTN -
51 224 T/LB Shift Indicator Light (MIT Only) SIL
~
52 362 Y EGR Vacuum Regulator Solenoid EVR

54 73 O/LB WOT A/C Cut Off WAC
56 349 DB Profile Ignition Pick-Up PIP
58 95 T/R Fuel Injector INJ

connector with DVOM probe will result in permanent
- -
601'000000000051 ( 0 " 0 0 0 0 0 0 0 0 0 0
0
41
damage to the pin connectors. Always probe as 40 000000000031 300000000000 21
directed, using the Breakout Box. 20 \... .0000000000 11 100000000000 1

ALL RIGHTS RESERVED
1.9L
Quick Test Codes and Code Definitions
CFI
12 r ~ Cannot control rpm during Self-Test high rpm check
13 0 ~ D.C. motor movement not detected
13 r ~ Cannot control rpm during Self-Test low rpm check
13 c ~ D.C. motor did not follow dashpot
14 c ~ PI P circuit failure
15 c ~ Keep Alive Memory (KAM) test failed
16 r ~ Idle rpm high with ISC retracted (OFF)
17 r ~ Idle rpm low with ISC retracted (OFF)
19 r ~ Rpm for EGR test not achieved
21 or ~ ECT sensor input is out of Self-Test range
22 orc ~ MAP sensor input is out of Self-Test range
23 orc ~ TP sensor input is out of Self-Test range
24 or ~ ACT sensor input is out of Self-Test range
31 orc ~ PFE circuit is below minimum voltage
32 rc ~ EPT circuit voltage low (PFE)
33 rc ~ EGR valve opening (PFE) not detected
34 0 ~ Defective PFE sensor
34 rc ~ EPT sensor voltage high (PFE)
35 orc ~ PFE circuit is above maximum voltage
38 c ~ Idle Tracking Switch (ITS) circuit open
41 c ~ No HEGO switching detected
42 r ~ HEGO sensor circuit indicates. system rich
51 oc ~ ECT sensor circuit open
53 oc ~ TP sensor input is greater than Self-Test maximum
54 oc ~ ACT sensor circuit open
-,
55 r ~ Keypower circuit open
58 0 ~ Idle Tracking Switch (ITS) circuit open
58 r ~ Idle Tracking Switch (ITS) closed/circuit grounded
61 oc ~ ECT sensor input is less than Self-Test minimum/circuit grounded
63 oc ~ TP sensor input is less than Self-Test minimum
64 oc ~ ACT sensor input is less than Self-Test minimum/circuit grounded
67 or ~ Neutral Drive Switch (NOS) circuit open; A/C input high
68 0 ~ Idle Tracking Switch (ITS) closed/circuit grounded
68 r ~ Idle Tracking Switch (ITS) circuit open
71 c ~ Idle Tracking Switch (ITS) shorted to ground on pre-position
73 0 ~ Insufficient throttle position change
84 or ~ EGR Vacuum Regulator (EVR) circuit failure
85 or ~ Canister Purge (CANP) circuit failure
87 orc ~ Fuel pump primary circuit failure
93 0 ~ TP sensor input low at maximum D.C. motor extension
95 oc ~ Fuel pump circuit open - ECA to motor ground
96 oc ~ Fuel pump circuit open - battery to ECA
98 r ~ Hard fault is present
99 r ~ EEC .system has not learned to control idle, ignore Codes 12 and 13
KEY: 0 = Key On Engine Off (KOEO) r = Engine Running (ER) c = Continuous Memory

ALL RIGHTS RESERVED
m
m
CYLINOCR HEATED
n
...
ENGINE THROTILE PRESSURE VEHICLE
;:
IOCNTlFlCATION OCTANE EXHAUST
HEGO SENSOR ADJUST' GAS OXyGEN
COOLANT POSITION AIR CHARGE FEEDBACK MASS SPEED
AT
~~~~~
TEMP SENSOR SENSOR TEMP SENSOR EGR (PFE) AIRFLOW SENSOR SELFTEST
f ~ m
GROUND (CIO) IOCT ADJ 1) (ECT) (TP) (ACT) (IF EOUIPPED) SENSOR (VSS)
rrJ
~
CONNECTOR 22_
r :~ '_R ~RR~l
,~w" I
a
~
\1:Ftl
J
o SELFTEST
INPUT
m
~
co
s-
' ., _ GRD RUN

...
CD
I ,
~ ~~~~S n
'" -"" l Ii I II II III In "T
SWITCH 6 26 49 : _ 29 7 46 46 46 27 26 9 50 40 37/57 36
D) fA
c
~,~~~"~
46 8 018 SERVICE I 48
ENGINE '0
SOON '0
UGH,!..........
(I) CD
n 3
8)
-I
34~ CD
29 HEGO
ECT
~ ~
7
~
6O-PIN
47~
25!f!!..
TO
IGNITION
RUN a -,j
I
20 40 60 27~
26~
9 MAF RTN
....
D) en
en
CD
MAF
~ VSSDIF(+)
6 VSS DIF (.)
n ~
co
CD
SIG RTN ~
4
6 --
8 D~A(-)
DATA (+) n
I
~~ STO/MIL ~
STI
48~ 10 SHIFT
~ -g' ,.. - ill

VRS
=----+
53 INDICA10R
LAMP
SENSOR
. VRS +
.......
.
~MODULE
111m
EDIS
COIL 2
COIL 1
Ii 10 IGNITION
START/RUN
I VRS.(\::.::=====~..:'. ~lnl -=
:
IGN G N D '
SAW
PIP
nm-- i

!
II .
, ,
J
IGNITION
COIL
i~
I l
-"-w.~~~
1 21 41 56 10M ------- 7 ~
4 INJ-4 I I I I
13 INJ.3
12 INJ.2
59iNJi
2 INJECTORS 3 4
58-
EVR 37/57
33 FP
22)SC
21 PWR
37 VPWR
57 10 IGNITION
RELAY
EGR (BAIT + IN START/RUN)
R~~~~T~R ---------1
(EVR) I
(IF EOUIPPED) HEDF FAN I
5~ ~~~i
1~ ~l
_ _ _- I ~-l
AlC
H.P. SWITCH
FPM SWITCH..:....-_~f-I
(IJ~"",
ALL RIGHTS RESERVED
tTl \c
."
..... r- ...A
AI3589-A
en

CD
1510 EECIV -Engine Supplement - Passenger Car
1.9L
EEC-IV Module Connector Pin Usage MA
SEFI
1 330 Bl/R Keep Alive Power KAPWR
3 159 W/BK Vehicle Speed Sensor (+) VSS (+)
4 153 R Ignition Diagnostic Monitor 10M
6 57 Bl Vehicle Speed Sensor (-) VSS (~)
7 62 Bl/W Engine Coolant Temperature ECT

8 121 Y/BK Data Communications Link (-) DATA (-)
9 87 GR/Y Mass Air Flow Return MAF RTN
10 707 GR/BK A/C Clutch ACC-
12 105 Y/O Injector 3 INJ 3
13 115 GR/O Injector 4 INJ 4
16 78 R/Bl Ignition Ground IGN GND
Self-Test Output/"SERVICE ENGINE
17 129 Y/BK STO/Mll
SOON" Light
19 102 BK/PK Fuel Pump Monitor FPM
21 83 Bl/O Idle Speed Control - Bypass Air ISC-BPA
22 103 lG Fuel Pump FP
25 109 W/GR Air Charge Temperature ACT
26 85 R/W Reference Voltage VREF
27 145 BLlY Pressure Feedback EGR (if EGR equipped) PFE
28 122 Y/Bl Data Communications Link (+) DATA (+)
29 118 GR/Bl Heated Exhaust Gas Oxygen Sensor HEGO
30 82 BR/Y Neutral Drive Switch (A/T only) NOS
Neutral Gear Switch and Clutch Engage
30 82 BR/Y
Switch (MIT only)
NGS & CES
31 866 R/BK High Electro Drive Fan HEDF

33 108 W/Bl EGR Vacuum Regulator (if EGR equipped) EVR
34 63 lG/BK Octane Adjust 2 OCT ADJ 2
35 719 Y/W Electro-Drive Fan EDF
36 156 lG/W Spark Angle Word SAW
37 101 W/R Vehicle Power VPWR
40 999 BK/GR Power Ground PWR GND
41 128 0 Cylinder Identification (+) CID (+)
42 127 BL/GR Cylinder Identification (-) CID (-)
43 171 GR/W Octane Adjust 1 OCT ADJ 1
46 63 lG/BK Signal Return SIG RTN
47 71 BR/W Throttle Position Sensor TP .

ALL RIGHTS RESERVED
EECIV - Engine Supplement - Passenger Car 15-11
1.9L
SEFI
Pin Circuit Wire Color Application 'Abbreviations
48 119 LG/Y Self-Test Input STI
Heated Exhaust Gas Oxygen Sensor
49 59 BK HEGO GND
Ground
50 143 BR/BK 'Mass Air Flow MAF
53 154 LG/R Shift Indicator Light SIL
54 702 BL/BK - WOT A/C Cut-out WAC
56 69 GR/W Profile Ignition Pick-up PIP
57 101 W/R Vehicle Power VPWR
58 106 Y Injector 1 INJ 1
59 116 GR/R Injector 2 INJ 2
60 999 BK/GR Power Ground PWR GND
Pin locations given for reference only. Probing 60 pin - -

damage to the pin connectors. Always probe as
directed, using the Breakout Box.
6 "000000000051
1
40
20
000000000031
0000,000000
@ 500000000000
300000000000
100000000000
41
21
1
11

ALL RIGHTS RESERVED
1~9L
Quick Test Codes and Code Definitions MA
SEFI
SERVICE CODE . SERVICE CODE DEFINITION
18 r ~ Spark Angle Word (SAW) circuit failure
19 0 ~ Failure in ECA internal voltage
19 c ~ CID circuit failure
21 or ~ ECT out of Self-Test range
24 or ~ ACT out of Self-Test range
26 or ~ MAF out of Self-Test range
29 c ~ Insufficient input from Vehicle Speed Sensor (VSS)
31 orc ~ PFE circuit below minimum voltage
32 rc ~ PFE circuit voltage low
33 rc ~ EGR valve opening not detected
34 0 ~ PFE sensor voltage out of range
34 rc ~ Exhaust Pressure high/PFE circuit voltage high
35 orc ~ PFE circuit above maximum voltage
41 c ~ No HEGO switch detected
45 c ~ Coil 1 primary circuit failure
54 oc ~ ACT indicated - 40F/circuit open
56 orc ~ MAF circuit above maximum voltage
61 oc ~ ECT indicates 254F/circuit grounded
64 oc ~ ACT indicates 254F/circuit grounded
66 rc ~ MAF below minimum voltage
67 or ~ Neutral Drive Switch (NOS) circuit open
72 r ~ Insufficient MAF change during Dynamic Response Test
73 r ~ Insufficient throttle position change during Dynamic Response Test
74 r ~ Brake ON/OFF circuit failure/not actuated during Self-Test
77 r ~ Brief WOT not sensed during SelfTest!operator error
79 0 ~ A/C ON/defrost on during Self-Test
83 0 ~ High Speed Electro Drive Fan (HEDF) circuit failure
84 or ~ EGR Vacuum Regulator (EVR) circuit failure
87 oc ~ Fuel pump primary circuit failure
88 0 ~ Electro Drive Fan (EDF) circuit failure
98 r ~ Hard fault is present - FMEM mode

ALL RIGHTS RESERVED
rn
rn
Mil CLUTCH
HEATED
EXHAUST ENGINE THROTTLE
MANIFOLD
' ABSOLUTE
POWER
EGR VALVE STEERING BRAKE
..m
~
n
n

<:
I
rn
I 30 ENGAGE
SWITCH
HEGO GAS OXYGEN
SENSOR
GROUND
SENSOR
(HEGO)
COOLANT
(ECT)
POSITION
(TP)
AIR CHARGE PRESSURE KNOCK POSITION PRESSURE ON-OFF
TEMPERATURE SENSOR TEMP. SENSOR SENSOR SENSOR SENSOR
(ACT) (MAP) (KS) (EVP)
SWITCH
(PSPSj
SWITCH
(BOO/
SELF-TEST
CONNECTOR ....
.......
::::s
ca
5"
~ U
STARTER
RELAY NEUTRAL
GEAR
S~~TCH I '~'~t'1~'J
t tI ! JII 'iii 11 . iii II 'iii i I r~
..
n
s:
CD
en
c
"0
"0
CE~SWnCH
~ i"
-
NEUTRAL
DRIVE
_
_ CIJ 3
I n
=- -I
".,.,..,SO ... OND 10
HEGO GND IGNITION CD
HEGO RUN ::::s
EeT t')
6O-PIN
TP
ACT
MAP a
s:
"0
I
20 4060 KS
EVP ....
.... en
en
CD
PSPS
BOO
10
IGNITION n ::::s
ca
VREF
~RTN
RUN
.,
CD
n
.,
I
22
58 INJBANKl
59 INJBANK2
3353 r-------------
~~ ~
CCO
EGRV
1 21 41
I
37~
21 ISC
V_PW
57_ _R
I r--37/57-~.gl~-~33~,l1-J~53t~:~~-~--ll..-------..,..........:------~--.:~------
I
I CONVERTER
CLUTCH
- TO
FUEl
37/57
I
22
OVERRIDE PUMP
SOlENOID
(CCO)
(All ONLY)
1 I\APWR
40~ I
OO~
i
,
54
"OCO NO "
""",,
'D 'CO I ~NG
~
.""
FAN
TEMP. SWITCH
FAN CON""""R
~~~~RE
CYCLIC
RUN C~CU"
m "'N"'ON TO
IGNITION
SWITCtl
AlC START/RUN A9902.()
CLUTCH CIRCUIT
mO~
ALL RIGHTS RESERVED
":"
''TJ:C.~
....nr- ~
en
~

flo)
15-14 EEC-IV - Engine Supplement - Passenger Car
2.3L
EEC-IV Module Connector Pin Usage OHC
EFI
'MUSTANG'
1 38 BK/O Keep Alive Power KAPWR
2 810 R/LG Brake On/Off BOO
3 330 Y/LG Power Steering Pressure Switch PSPS
4 11 DG/Y Ignition Diagnostic Monitor IDM
17 657 T Self-Test Output/"CHECK ENGINE" Light STO/MIL
21 264 W/LB Idle Speed Control - Bypass Air ISC-BPA
23 310 Y/R Knock Sensor KS
24 348 LG/P A/C Demand ACD
25 162 LG/R Air Charge Temperature ACT
27 352 BR/LG EGR Valve Position EVP
30 771 PlY Neutral Drive Switch (A/T Only) NDS
30 771 PlY Neutral Gear Switch and Clutch Engage
Switch (MIT Only) NGS & CES
33 360 D~ Exhaust Gas Recirculation Vent EGRV
49 89 0 Heated Exhaust Gas Oxygen Sensor Ground HEGO GND
52 362 Y Exhaust Gas Recirculation Control EGRC
53 237 O/Y Clutch Converter Override (A/T Only) CCO
54 73 O/LB W.O.T. A/C Cut Off WAC
57 361 A Vehicle Power VPWR
58 96 T/O- Injector Bank 1 INJ Bank 1

- -
000000000051 @ O O 0000000 0 0
0
41
to the pin connectors. Always probe as directed, using the
Breakout Box.
6;1
40
20
000000000031
0000000000 ,
300000000000
100000000000
21
1
11

ALL RIGHTS RESERVED
EEC-IV ~ Engine Supplement - Passenger Car 15-15
2.3L
Quick Te~t Codes and Code Definitions OHC
EFI
SERVICE CODE SERVICE C.ODE DEFINITION
16 r ~ Rpm too low to perform EGO test
18 c ~ 10M circuit f~ilure/SPOUT circuit grounded
22 orc ~ MAP out of Self-Test range
25 r ~ Knock not sensed during Dynamic Response Test
31 orc ~ EVP circuit below minimum voltage
32 r ~ EGR not controlling
33 r ~ EGR valve not returning to closed position
34 r ~ EGR valve opening not detected
35 r ~ Rpm too low to perform EGR test
42 r ~ HEGO sensor circuit indicates system rich ,
52 0 ~ PSPS circuit open
64 oc ~ ACT indicated 254F/circuit grounded
67 0 ~ Neutral Drive Switch (NOS) circuit open/A/C ON
72 r ~ Insufficient MAP change during Dynamic Response Test
74 r ~ Brake On/Off (BOO) circuit open/not actuated during test
75 r ~ Brake On/Off (BOO) circuit closed/ECA input open
83 0 ~ EGRC solenoid circuit failure
84 0 ~ EGRV solenoid circuit failure
87 0 ~ Fuel pump primary circuit failure
89 0 ~ Converter Clutch Override (CCO) circuit failure
NO CODES ~ Unable to initiate Self-Test or unable to output Self-Test. codes

ALL RIGHTS RESERVED
~
(II

~
MfT G)
'ifd
START
'G SW N N:~TRAL
rn
.....
DRIVE
SWIlCH
~
AfT
~
~
STARTER
RELAY ......n~
.....
C
(MIL) (IJ
n
f :::r
60-PIN
~
a
20 40 60
TO
IGNITION
RUN .......
C
n
, .... ---------" ~
,t '. I \
II
\ I \: ~CON~~~TOR
- ~
, 0
. u .. .., c: 0
m
1 21 41 ::::L '=" m
o
;:
, I I 37/57' '
I
m
:::J
co
s
CD
en
c
"a
"a
CD
3
-I
CD
-54--+,
I
43
:::J
WL r"'. h- I 'V
S
fI)
ALL RIGHTS RESERVED
AlC OEM.
rn~~
CYCLIC
PRESSURE SWITCH fit
A13585-A' CD
SWITCH
:::J
." (.Q co
~ r- ...
CD
o
...
S
2.3L
EFI
MUSTANG
1 38 BY/O Keep Alive Power KAPWR
3 150 DG/W Vehicle Speed Sensor (+) VSS DIF (+)
4 11 DGIY Ignition Diagnostic Monitor IDM
6 563 O/Y Vehicle Speed Sensor (-) VSS DIF (-)
9 701 W/P Data Communications Link (-) Data (-)
10 883 PK/LB A/C Cyclic Switch ACCS
14 967 DB/O Mass Air Flow MAF
15 968 T/LB Mass Air Flow Return MAF RTN
17 657 T Self-Test Output/"SERVICE ENGINE SOON" Light STO/MIL
20 57 BK Case Ground CASE GND
21 264 W/LB Idle Speed Control - Bypass Air ISC-BPA
25 162 LG/R Air Charge Temperature ACT
26 351 O/W Voltage Reference VREF
28 702 W/BK Data Communications Link (+) Data (+)
30 771 PlY Neutral Drive Switch (AiT Only) NDS
31 101 GY/Y Canister Purge CANP
Neutral Gear Switch and Clutch Engage
30 771 PlY
Switch (MIT Only)
NGS & CES
33 360 DG EGR Vacuum Regulator EVR

43 348 LG/P .AlC Demand ACD
45 358 LG/BK Barometric Pressure Sensor BP
49 89 0 Heated Exhaust Gas Oxygen Sensor Ground HEGOG
52 435 Y/LB Shift Solenoid (AiT Only) SS 3/4
53 77 DB/Y Clutch Converter Override (AiT Only) CCO
57 361 R #
Vehicle Power VPWR
58 96 T/O Injector Bank 1 INJ Bank 1
.. -
Pin locations given for reference only. Probing 60 pin connector with
DVOM probe will result in permanent damage to the pin connectors.
60rO
40
00000000051 @ O O 000000000
000000000031 0
300000000000
41
21
Always probe as directed. using the Breakout Box.
20 \. 0 000000 000 11 10 000 00 000 00 1

ALL RIGHTS RESERVED
2.3L
Quick Test Codes and Code Definitions MA
EFI

11 orc System PASS
12 r Cannot control rpm during Self-Test high rpm check
13 r Cannot control rpm during Self-Test low rpm check
14
15
c
0 PIP circuit failure
ECA Read Only Memory (ROM) test failure
15
16
c
r
ECA Keep Alive Memory (KAM) test failed
Rpm to low to perform EGO test
18
18
r
c SPOUT circuit open
IDM circuit failure/SPOUT circuit grounded
19
21
0
or Failure in ECA internal voltage
ECT out of Self-Test range
22 orc
BP out of Self-Test range
23
24
or
or TP out of Self ~ Test range
ACT out of Self-Test range
25 r
Knock not sensed during Dynamic Response Test
26
29
or
c Mass Air Flow out of Self-Test range
Insufficient input from VSS
31 orc
EVR circuit below minimum voltage
32
33
orc
rc EVP voltage below closed limit
EGR valve opening not detected

34 orc EVP voltage above closed limit
35 orc EVP circuit above maximum voltage
41 r HEGO sensor circuit indicates system lean
41
42
c
r
No HEGO switch detected
HEGO sensor circuit indicates system rich
51
52
oc
0
ECT indicated - 40F/ circuit open
PSPS circuit open
53 oc TP' circuit above maximum voltage

54 oc ACT indicated - 40F/ circuit open
56 oc Mass Air FLow circuit above maximum voltage
61 oc ECT indicated 254F/circuit grounded

63 oc TP circuit below minimum voltage
64 oc ACT indicated 254F/circuit grounded
66 rc Mass Air Flow circuit below minimum voltage
67
72
0
r Neutral Drive Switch (NDS) circuit open
Insufficient MAF change during Dynamic Response Test
73
74
r
r Insufficient TP change during Dynamic Response Test
Brake On/Off (BOO) circuit failure/not actuated during test
77
79
r
0
Brief WOT not sensed during Self-Test/Operator error
A/C on/defrost on during Self-Test

84 0 EVR solenoid circuit failure
85 0 CANP solenoid circuit failure
86 0 3-4 Shift Solenoid circuit failure
87
89
0
0 Fuel pump primary circuit failure
Converter Clutch Override (CCO) circuit failure
95
96
oc
oc Fuel Pump Secondary Circuit failure
Fuel Pump Secondary Circuit failure
98
NO CODES
r
Hard fault is present - FMEM mode
Unable to initiate Self-Test or unable to output Self-Test codes
CODES NOT LISTED
KEY: 0 =

Key On Engine Off (KOEO)
Service codes displayed are not applicable to the vehicle being tested
r = Engine Running (ER) c = Continuous Memory

ALL RIGHTS RESERVED
m
m
0

m =<
n---
HEATED ENGINE AIR MANIFOLD POWER ft) I
m
....
EXHAUST GAS COOLANT THROTTLE CHARGE ABSOLUTE STEERING VEHICLE'
~
...
OXYGEN TEMP POSITION TEMP PRESSURE PRESSURE PRESSURE SPEED
IGN
START HEGO SENSOR SENSOR SENSOR SENSOR SENSOR FEEDBACK SWITCH SENSOR SELF-TEST CO
SWITCH GROUND (HEGO) (PSPS) 3"
n
(D
~
en
SELF-TEST
INPUT s c
STARTER
RELAY
(STI)
'f ---
C/)
""CD
3
48
n
-I
(D
:r
ft)
::s
a
s
"'U
I
6O-PIN
20 40 60 ....
.... UJ
UJ
CD
::s
"='
n
10
IGNITION
RUN ..
co
CD
, TO
IGNITION RUN INJECTORS
..
0
I
CIRCUIT 3 4
-""'-IL IGNITION ONLY
COIL
TFI
CONNECTOR
;~~;~~~~ t;.=----I
.m" 51
r----...,
I I I
I 37/57 6 t t
I 31
1 21 41
I
v ....m . , I 37/57 VPWR I
lAIR I CANISTER
IMANAG 1 I TO
PURGE FUEL
I(AM1) I
L . J SOLENOID
(CANP)
PUMP
FOR 2.3L HSC ONLY
r"n U11'tU 40
, PWR GND 60 ""k>
TO
IGNITION
SWITCH
BATT +
START/RUN
CIRCUIT
Al1512-C
m:C~
~
ALL RIGHTS RESERVED
~C/)~
"'nr- ....U'I
....
CD
I
2.3L
EECIV Module Connector Pin Usage HSC
EFI
1 37 Y Keep Alive Power KAPWA
3 150 DG/W Vehicle Speed Sensor (+) VSSDIF (+)
6 563 O/Y Vehicle Speed Sensor VSSDIF (-)
10 198 T/Y A/C Cycling Switch ACCS
Self-Test Outputl"CHECK ENGINE" or
17 201 T/R
"SERVICE ENGINE SOON" Light STO/MIL

21 376 BR/W Idle Speed Control - Bypass Air ISC-BPA
22 238 O/LB Fuel Pump Relay FP
30 614 GY/O Neutral Drive Switch (A/T Only) NOS
30 614 GY/O Clutch Engage Switch CES
33 362 Y EGA Vacuum Regulator Solenoid EVA
46 359 BK/W Signal Return Ground SIG ATN
51 100 W/R Air Management 1 (HSC +) AM 1
53 224 T/LB Shift Indicator Light SIL
54 73 O/LB WOT A/C Cut Off WAC
59 96 T/O Injector Bank 2 INJ Bank 2
Pin locations given for reference only. Probing 60 pin - -

damage to the pin connectors. Always probe as directed,
using the Breakout Box.
I
60 '000000000051 @OOOOOOOOOOO
40, 0 0 00000 00031
20 \.. 0 000 000 000
0
300 000 0 000 00
10 0 0 0 0 0 0 0 0 0 0
41
21
1
"

ALL RIGHTS RESERVED
EEC-IV - Engine Supplement - Passenger Car 1521
2.3L
Quick Test Codes and Code Definitions HSC
EFI
11 orc ~ System PASS -.
15 0 ~ ROM test failure
15 c ~ Keep Alive Memory (KAM) test failure
23 or ~ TP sensor input is out of Self-Test range
29 c ~ Insufficient input from the Vehicle Speed Sensor (V$S)
32 rc ~ PFE circuit volt~ge low
34 rc ~ Excessive exhaust back pressure/PFE circuit voltage high
52 0 ~ PSPS circuit is open
52 r ~ PSPS always staying open or closed .
53 oc ~ TP sensor input is greater than Self-Test maximum voltage
61 oc ~ ECT sensor circuit grounded
63 oc ~ TP sensor input is less than Self-Test minimum voltage
64 oc ~ ACT sensor circuit grounded
67 0 ~ Neutral Drive Switch (NOS) circuit open; A/C ON
82 0 ~ Air Management 1 (AM 1) circuit failure
84 0 ~ EGR Vacuum Regulator (EVR) circuit failure
85 0 ~ Canister Purge (CANP) circuit failure
95 oc ~ Fuel pump circuit open/ECA to motor ground
96 oc ~ Fuel pump circuit open/battery to ECA

ALL RIGHTS RESERVED
~
en

...rn
HEATED ~
EXHAUST ENGINE MANIFOLD EGR POWER ~
,
GAS COOLANT THRonLE AIR CHARGE ABSOLUTE VALVE STEERING VEHICLE SPEED
1
IGN. OXYGEN TEMP. POSITION TEMP. PRESSURE POSITION PRESSURE SPEED CONTROL
START SW. HEGO SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SWITCH SENSOR COM SW.
(Q
~
NEUTRAl GROUND (HEGO) (ECT) {TP} (ACT) (MAP) (EVP) (PSPS) (VSS) (SCCS) BAn + VIP
~ ~ ~
CONNECTOR ~
o~,
l ~ a
~"m t BRAKE
:2.
IIG~Nli Iii ~ ~,
00
SWITCH SWITCH I
n,.
30 NOS
:;iW
STARTER
RELAY
49
I
PWR
GND 29 7 46 46
IT
46 27 46
Iii Iii IT ]I I I UGH

39 50' 2
BRAKE
T 46
J
I
" .. 22
...
n
D
47 TP en
25
45 ACT
MAP I I I '
g.
27~
23~
6 VSS DIF(-) * BAn+
AFTER
HORN
"CHECKf
ENGINE"
LIGHT
(MIL)
(Q
a
an
3 VSS DIFl+) RELAY
6o-PIN 50~
2 BOO TO IGNITION
20 40 60 RUN
26~
46 SIG. RET
9 1DATAiT
I DATA (+)
~~ STO/MIL
48~
Q.Qb...--. TO INSTRUMENT PANEL
344 10M
~P
221< OHMS
_
TO COIL INJECTOR
~
56 SPOUT ' \
36 IGN GND
~~ CASE GND
,____________ TFI
CONNECTOR i 37/57 NC OEM.

SW.
CY~L1C
PRES. SW.
m
58.LW. i 1-~ 1O-+- m
35~ o
42~
13 SOL (+) <:
3'~
33~ I
1 21 41
TO IGNITION m
~
t~
SWITCH
37~ 024
57 VPWR J f--t1 I
ca
m
TO COOLING OHMS 3'
24~
r37J~71 37~/573~ 14~21 F~:~
21~
4'~
iij Jl 4 1
3
~0
TO
INERTIA
PUMP
_~~-,~ (-)
CD
en
c:
""3CD
SWITCH NC
IDLE
o FPM ICLUTCH
SPEED EGR CANISTER o
VEHICLE 8 (+)
Cg~~~~L
-
CONTROL CONTROL PURGE INTEGRATED
DC MOTOR (EVR) (CANP) RELAY CD
'-
~
C S GND (ISC) CONTROLLER'
"REFER TO
:-
22' FP
KAPWR
PWR GND
~ 40/60
INTEGRATED
CONTROLLER
IN THIS
SECTION
I
."
I
: PWR GND UJ
ALL RIGHTS RESERVED
54 WAC
n-n~ til
CD
52 HEDF
5: EDF
KEY POWER
-nt-c.n
...nr-
~
ca
...
CD
A9132E
NOTE: WIRING SCHEMATIC SHOWS PIN OUT LOOKING INTO HARNESS CONNECTOR o
...
D)
2.5L
EEC-IV Module Connector Pin Usage FLC
CFI
3 150 DG/W Vehicle Speed Sensor (+) VSS (+)
5 16 R/LG Key Power KPWR
6 563 O/Y Vehicle Speed Sensor (-) VSS (-)
9 695 BK/O Data (-) Data (-)
10 883 PK/LB A/C Cycling Switch ACCS
13 144 O/Y Vehicle Speed Control Solenoid SOL (+)
17 201 T/R Self-Test Outl"Check Engine" Light STO/MIL
21 382 Y/BK Idle Speed Control (DC Motor) ISC (+)
22 97 T/LG Fuel Pump Fp
24 209 W/R Idle Tracking Switch ITS
25 357 LG/P Air Charge Temperature ACT
28 696 O/BK Data (+) Data (+)
29 94 DG/P Heated Exhaust Gas Oxygen (Sensor) HEGO
30 199 LB/Y Neutral Drive Switch NOS
33 360 DG EGR Vacuum Regulator (Solenoid) EVR
34 305 LB/PK Data Output Link DOL
35 146 W/PK Speed Control Vent (Solenoid) SCVNT
36 324 Y/LG Spark Out SPOUT
39 461 0 Speed Control Command Switch Ground SCCS GND
(Continued)

ALL RIGHTS RESERVED
2.5L
EEC-IV Module Connector Pin Usage FLC
CFI
41 377 W Idle Speed Control - (DC Motor) ISC (-)
42 145 GY/BK Speed Control Vacuum (Solenoid) SCVAC
45 358 LG/BK Manifold Absolute Pressure (Sensor) MAP
46 359 BK/W Signal Return (Ground) SIG RTN
47 355 DG/LG Throttle Position (Sensor) TP
48 200 W/BK Self-Test Input STI
Heated Exhaust Gas Oxygen (Sensor)
49 89 0 HEGO GND
Ground
50 151 LB/BK Speed Control Command Switch SCCS
52 639 PK High Electro Drive Fan HEDF
54 331 R Wide Open Throttle (WOT) A/C Cut Off WAC
55 197 T/O Electro Drive Fan (Low) EDF
56 349 DB Profile Ignition Pick-up PIP
58 95 T/A Injector INJ

- -
'000000000051 @OOOOOOOOOOO
0
41
damage to the pin connectors. Always probe as 6:1
40
20
000000000031 300000000000 21
1
directed. using the Breakout Box. 0000000000" 100000000000

ALL RIGHTS RESERVED
m
m
o
..... =<
a FPM
llNERTl1
:=.... I
5 1.1 SWITC.
~ m
.... ~
\ 1\.12 "- I ...

tea co
5'
22
FP
I
,
"- 18
FUEL
-j
I
..1.......
VVVVI/V
FUEL ~
PUMP ....
DJ
~
CD
en
c::
VPWR ,, 24
PUMP
RELAY
-:1 Q. "0
"'C
37 CD
57
VPWR I n 3
-I
CD
rn
8 Q ~
'", ""; :=....
IGNITION I~ I
I
.............
. IIWUIIV
...
SWITCH
'VOLTAGE
INVERTER ~C J ,.. T Q
"a
D)
6OPIN
BATTERY START/RUN
~
, 13
-----~
l 1
POWER
RELAY
.....
.....
.....
(I)
(I)
2040 60
1.1 CD
, 1
-. ...
~
1______ I
1 ::::I
co
I 71/ 1 .... .,CD
. A A
. y ,
"- 2
-----.,I -!
3
(I} o
1 J
I'
1 I vee
EDF
EDF , 14 1 _L
RELAY J 4.... , n .,
D)
=-
55 ; vwwv
i
'--~---
').
'VOlTAGE
:
1 ~
....,
COOLING
FAN ~
"-
~
,
6
7
INVERTER
1 ~
--:: a
HEOF 17
HEDF
RELAY
-:
L
I ....
DJ

52 "-
; UUVIIW
'---
n
AlC OEM.
SWITCH ~
CYCLIC PRESSURE SWITCH
_, , 21
r-----L:: 23 .I
ACCS BATT+'-- T' SOLID i'
1
10 STATE
WAC 22
54 ,"- RELAY
"- 15
L.-...-
- ~~UTCH~
1 ~
: 16 C.OIL 1
1/ 1
'INCLUDES TIME DELAY
n"'~
ALL RIGHTS RESERVED
CONTROLLER HARNESS CONNECTOR CONTROLLER MODULE CONNECTOR

A9S04F
."r-en
..... nr- """
U1
N
U1
2.5L
Integrated Controller Pin Usage FLC
CFI
Pin Circuit Color Application Abbreviations
1 181 BRIO EDF Power Into Controller Batt (+)
2 181 BRIO EDF Power Into Controller Batt (+)
3 228 BRIY H/EDF Power to Fan PTF
4 228 BR/Y H/EDF Power to Fan PTF
5 787 PK/BK Power to the Pump PTP
6 38 BK/O HEDF Power Into Controller Batt (+)
7 38 BK/O HEDF Power Into Controller Batt (+)
8 37 Y Battery Voltage (Power Relay) Batt (+)
12 38 BK/O Power to WOT AIC Cutoff PT/WAC
13 16 R/LG Keypower KPWR
14 197 T/O EDF Circuit EDF
15 60 BK/LG Vehicle Ground PWR GND
16 57 BK AIC Ground AIC GND
17 639 PK HEDF Circuit HEDF
18 97 T/LG Fuel Pump Circuit FP
21 883 PK/LB AIC Power ACCS
22 331 R WOT AIC Cut Off WAC
23 347 BK/Y A/C Power to Clutch Coil PTAC

ALL RIGHTS RESERVED
2.5L
Quick Test Codes and Code Definitions FLC
CFI
13 0 ~ D.C. motor movement not detected
13 c ~ D.C. motor does not follow dashpot
15 0 ~ ECA ROM test failure
16 r ~ Idle rpm high with ISC retracted/off
17 r ~ Idle rpm low with ISC retracted/off
21 or ~ ECT sensor out of Self-Test range
22 orc ~ MAP sensor out of Self-Test range
23 orc ~ TP sensor out of Self-Test range
24 or ~ ACT sensor out of Self-Test range
32 orc ~ EVP voltage is below closed limit
34 orc ~ EVP voltage above closed limit
35 orc ~ EVP circuit above maximum voltage
38 c ~ Idle Tracking Switch (ITS) circuit open
51 oc ~ ECT sensor indicated - 40F/circuit open
52 r ~ PSPS circuit did not change states
53 oc ~ TP sensor circuit above maximum voltage
54 oc ~ ACT sensor indicated - 40F/circuit open
55 r ~ Keypower circuit open
58 0 ~ Idle Tracking Switch circuit open
58 r ~ Idle Tracking Switch closed/circuit grounded
61 oc ~ ECT sensor indicated 254F/circuit grounded
63 oc ~ TP sensor circuit below minimum voltage
64 oc ~ ACT sensor indicated 254F/circuit grounded
67 0 ~ Neutral Drive Switch (NOS) circuit open; A/C ON
68 0 ~ Idle Tracking Switch (ITS) failed closed/circuit grounded
68 r ~ Idle Tracking Switch (ITS) circuit failed open
(Continued)

ALL RIGHTS RESERVED
1528 EEC-IV - Engine Supplement - Passenger Car
2.5L
Quick Test Codes and Code Definitions FLC
CFI
71 c ~ Idle Tracking Switch (ITS) Shorted-To-Ground on pre-position
72 c ~ Power interruptlreinitialization detected
73 0 ~ Insufficient throttle position change
74 r ~ Brake On/Off (BOO) circuit failure - not actuated during Self-Test
83 0 ~ High speed electro drive fan (HEDF) circuit failure
87 oc ~ Primary fuel pump circuit failure
88 0 ~ Electro-drive fan (EDF) circuit failure
93 0 ~ TP sensor input low at maximum D.C. motor extension
99 r ~ EEC system has not learned to control idle, ignore Codes 12 and 13

ALL RIGHTS RESERVED
m
DUAL HEATED EXHAUST ENGINE AIR MANIFOLD m
GAS OXYGEN VEHICLE 0
;:
COOLANT THROTILE CHARGE ABSOLUTE PRESSURE
IGN START SWITCH

POWER
GROUND -=-
(HEGO) SENSOR TEMP
(ECT)
SENSOR
POSITION
(TP)
SENSOR
TEMP
(ACT)
SENSOR
PRESSURE
(MAP)
SENSOR
FEEDBACK
(PFE)
EGR
SPEED
SENSOR
(VSS)
SELF-TEST
CONNECTOR rn
.... I
tmfiTI~
(Q
NEUTRAL ~ m
...n~
DRIVE :::::J
SWITCH ca
STARTER
'1 SO
RELAY
CD
29
30 NOS NT ONLY
43~
37/57
43
7 I 26 46 47 46 25 46 45 26 27 46 26 ....
S en
c
'tJ
'tJ
29~ (I) CD
50-PIN 7CT 3
20 40 60
47.If.
25 ACT
45 MAP
S-
(Q -I
CD
:::::J
27 PFE
26~ a "
.......
I
3 VSS
46 SIG RTN
POWER
":'" GROUND
S U)
U)
17..IQ CD
48~ n :::::J
ca
56..E!!:
36 SPOUT ...
CD
.
58" i
16~ 0
49~ TFI 15 AMP I
CONNECTOR AUXILIARY FUSE PANEL
20~
22 _F_P _
58~
59~
51 AMI
31 CANP
1 21 41
33 EVR
52 SS 3/4 I I I
21 ISC I 33 31 51
:e
37 VPWR t . . 53..., 5
37/57 ' I I '
r~
WR
SERVICE PIN IDLE CONVERTER EGR CANISTER THERMACTOR

CONNECTOR SPEED CLUTCH VACUUM PURGE AIR
CONTROL OVERRIDE REGULATOR (CANP) SOLENOID
BYPASS SOLENOID (EVR) (AM1)
AIR AND SS 3/4
(ISC-BPA) i(AfT ONLY)
CCO FUSE 31
53 I
1 AMP
1~
40~
60~
342h TO
FUEL COMPUTER
::Tc* BATT + 4 '--e

r"~~
~* 54
NC
FROM
IGNITION
SWITCH
START/RUN
AIC DE-ICE THREE-WAY CLUTCH CIRCUITS
m~
.,,\c
SWITCH WOT AIC
RELAY (WAC)
ALL RIGHTS RESERVED
NOTE: WIRING SCHEMATIC SHOWS PIN OUT LOOKING INTO HARNESS CONNECTORS
SCHEMATIC MAY NOT REPRESENT ALL TRUE CONNECTOR SHAPES A13586-A
.... r- ...A.
U'I
N
CD
2.9L
EFI
1 54-28 BK/BL Keep Alive Power KAPWR
3 2 Y/BR Vehicle Speed Sensor (Hall Effect) VSS
7 31B-75 BR/GN Engine Coolant Temperature ECT
10 54-47 BK/Y A/C Clutch ACCS
15 31B-28 BR/BL 314 Shift Solenoid 314 SS
16 31-29 BR Ignition Ground IGN GND
17 31B-40 BR/GR Self-Test Output STO
18 546 BK/R Brake ON/OFF BOO
19 54-50 BK/GR Kick Down Switch KDS
20 31-49 BR Case Ground CSE GND
21 31 B-73 BR/Y Idle Speed Control (Bypass Air) ISC8PA
22 9-25 BL/R Fuel Pump FP
23 - - Octane Adjust OCT ADJ.
25 31 B-17 BR/Y Air Charge Temperature ACT
26 31B20 BR/BK Reference Voltage VREF
28 31-29 BR Idle Adjust IDLE ADJ.
29 9-40 BL/W Heated Exhaust Gas Oxygen Sensor - Right HEGO-R
30 318-30 8R/W Neutral Drive Switch (Auto Trans Only) NOS
31 318-10 8R/W Canister Purge Solenoid CANP
34 318-34 BR/Y Data Output Link DOL
36 9-18 BL/R Spark Output SPOUT
37 16-6 BK Vehicle Power VPWR
40 31-29 BA Power Ground PWR GND
43 9-39 BL/BK Heated Exhaust Gas Oxygen Sensor - Left HEGO-L
45 31B-76 BA/Y Manifold Absolute Pressure (Sensor) MAP
46 31-75 BA Signal Return SIG RTN
47 31 B-13 BA/GA Throttle Position (Sensor) TP
48 9-20 BL/GA Self Test Input STI
49 31-31 BA Heated Exhaust Gas Oxygen Sensor Ground HEGO GND
53 31B-39 BA Converter Clutch Override CCO
54 31B-35 BR/GA Wide-Open Throttle (WOT) A/C Cutoff WAC
56 9-17 BL/Y Profile Ignition Pickup PIP
57 15-6 BK Vehicle Power VPWR
58 3173 BA Injector Bank 1 INJ Bank 1
59 31-74 BA Injector Bank 2 INJ Bank 2
60 31-29 BA Power Ground PWR GND

-
60 '000000000051
-
500000000000 41
damage to the pin connectors. Always probe as 40 000'000000031@300000000000 21
directed, using the Breakout Box. 20 0000000000
11
100000000000 1
.....

ALL RIGHTS RESERVED
2.9L
EFI
12 r ~ Unable to control rpm during Self-Test high rpm check
13 r ~ Unable to control rpm during Self-Te"st low rpm check
14 c ~ PI P circuit failure
19 0 ~ Failure in EEC internal voltage
22 orc ~ MAP sensor out of Self-Test range
23 or ~ TP sensor out of Self-Test range
24 or ~ ACT sensor out of Self-Test range
29 c ~ Insufficient input from the Vehicle Speed Sensor (VSS)
51 oc ~ ECT sensor indicates 254F/circuit grounded
54 oc ~ ACT sensor indicates - 40F/circuit open
57 0 ~ Octane Adjust service pin in use
59 0 ~ Idle Adjust service pin in use
61 oc ~ ECT sensor indicated 254F/circuit grounded
64 oc ~ ACT sensor indicated 254F/circuit grounded
67 0 ~ Neutral Pressure Switch (NPS) circuit open; A/C ON
72 r ~ Insufficient MAP output change during Dynamic Response Test
73 r ~ Insufficient TP output change during Dynamic Response Test
87 oc ~ .Primary fuel pump circuit failure
89 0 ~ Clutch converter override (CCO) circuit failed
91 r ~ HEGO sensor indicates system lean
92 r ~ HEGO sensor indicates system rich
" KEY: 0 = Key On Engine Off (KOEO) r = Engine Running (ER) c = Continuous Memory

ALL RIGHTS RESERVED
~~ ~=~
FOR 3.0L PROBE ONLY (AfT)
TO~EAT
4/3
19 THS 12
r:.- - - ,
I
I
I HEGO
!GR~ND
HEATED
EXHAUST
GAS OXYGEN
SENSOR
(HEGO)
ENGINE
COOLANT
SENSOR
TEMP. till , tIl M
FOR 3.0L PROBE ONI:
1tW P~NSOR
TOt<EAT
ROTILE
H SITION
S (TP)
AIR CH~RG
TEM'
(ACT)
SENSO
'
R
MANIFOLD
E ABSOlUTE
rI ~ '-1I PRESSU~~
SENSOR
KNOCK
IKS) 'FEEDIlA
PRESSURE 1(49 STATES',
SENSOR
CC
(MAP)
II& CANADA
ONLY
)
EGR(6~~~ 'I~ ~
(CALIF.
I
POWER
SW"CH
r - -, VEHICLE
"EER'NG ICONTROl,
PRESSURE sPEED I SENSOR
(PSPS) I (SCCS)
L
I
SPEED BAn.
COM "" r IVSS)
-,
t
~SWITCH BRAKE
__ =1
rm 0
~
SELF-TEST SELF-TEST
CONNECTOR
INPUT
(STI)
:~ HEGOG ~II
(ECT) BRAKE,
7 :1" 46
~ I i ~NLVI
I
I I I'
29 HEGO 46 47 .] 125 50 39 3' UGHT
7 ECT
47 TP
25~
45~
23&
26 46
"'r( j(ir r II
I 46
BATI(+)
I
L:-=-
"
_ --J
I
9
ie
17 48
ef
AFTER
60-PIN 27~ HORN
20 40 60 26.YB..5.E RELAY
24~ "CHECK
50~ ENGINE"
LIGHT
6'{SS DIF(-)
3 VSS DIF(+1
2 BOO TO IGNITION
RUN
46~
17~
9 DATA (-) ., TO INSTRUMENT.
28~
48~
~ f~~~~ ONLY)
, TO IGNITION RUN i ~. ,
51- HT~~ t
HEATED WINDSHIELD
34.Q.Qh TO IN:l~~~ENT "r22KOHMS (495rATES & CANADA ONLY)"" CONTROLLER
4.lflli1
(T--=m-~n
~"-({R}t
56~
36~ -l
FRONT
1 21 41
16.!Q!i.Q.!':!Q.
20~
" L
=--- t SB
, TFI
CONNECTOR
INJECTORS OF
VEHICLE rn
58~ rn
-~ I
59~
22_
F_P _ ~ oI
35 SCVNT BATT+'-~ <:
~S8 1
42 SCVAC A/C OEM CYCLIC
13 SOL(+) 'I SW. PRES. SW I
31 CANP rn
33 EVR ~
21 ISC BPA CO
37 VPWR S'
57 VPWR CD
en
C
"'0
"'0
52 HEDF
55 EDF
INERTIA
SWITCH .----4.....--+.---U...++--1!------1I-....J CD
3
-I
8 FPM CALIF. ONLY CD
1 KAPW
~
40 PWR GND
60 PWR GND 40 1
"
39 SCCS GND
10 AC S BATIERY DJ
(I)
rn~
ALL RIGHTS RESERVED
54 WAC (I)
I INTEGRATED CD
54
I
RELAY
CONTROLLER' -nO ~
CO
"EXCEPT 3.0L EFI PROBE /4EAT)
'REFER TO INTEGRATED CONTROLLER IN THIS SECTION A9133F --r- ...
CD
o
...
DJ
3.0'L
EFI
Probe
1 84 Bl/R Keep Alive -Power KAPWR
3 241 BK/R Vehicle Speed Sensor (+) VSS DIF (+)
4 730 GR Ignition Diagnostic Monitor 10M
6 247 BK/Bl Vehicle Speed Sensor (-) VSS DIF (-)
7 724 Y/R Engine Coolant Temperature Sensor ECT
8 703 W/Bl Fuel Pump Monitor FPM
9 742 0 Data Communications Link (-) DATA (-)
10 176 PK/BK A/C Cycling Switch ACC
16 750 W, Ignition Ground IGN GND
17 _ 727 W/Bl Self-Test Outputl"CHECK ENGINE" Light STO/Mll
21 710 W/R Idle Speed Control-Bypass Air ISC-BPA
22 179 Bl/GR Fuel Pump FP
24 718 BR/R Power Steering Pressure Switch .. PSPS
25 726 Y Air Charge Temperature Sensor ACT
26 813 lG/R Reference Voltage VREF
27 725 Y/Bl Pressure Feedback EGR (California only) PFE
28- 741 O/Y Data Communications Link (+) DATA (+)
29 94 GR/R Heated Exhaust Gas Oxygen Sensor HEGO
30 716 R/Bl Neutral Drive Switch (AID NOS
30 716 R/Bl Neutral Gear and Clutch Engage- Switch (MIT) NGS and CES
31 709 W/BK Canister Purge Solenoid CANP
33 708 W EGR Vacuum Regulator Solenoid (California only) EVR
34 777 BK/GR Data Output Link DOL
36 752 R Spark Output SPOUT
37 702 R/BK Vehicle Power VPWR
40 61 B~(/W Power -Ground PWR GND
45 711 W/GR Manifold Absolute Pressure Sensor MAP
46 829 lG/Y Signal Return Ground SIG RTN
47 ~15 lG/BK Throttle Position Sensor TP
49 89 BK/lG Heated Exhaust Gas Oxygen Sensor Ground HEGO GND
52 177 PK High Electro-Drive Fan HEDF
54 175 -A Wide Open Throttle A/C Cut-off WAC
55 178 Y/GR Electro Drive Fan (Low) EDF
56 751 BK Profile Ignition Pi~k-up PIP
57 702 R/BK Vehicle Power' VPWR
~8 706 Y Injector Bank 1 INJ Bank 1
59 705 Y/BK Injector Bank 2 INJ Bank 2
60 60 BK/Y Power Ground PWR GND
Pin locations given for reference only. Probing 60 pin connector

with DVOM probe will result in permanent damage to the pin
-
'00000000005' @OOOOOOOOOOO
0
- 41
connectors. Always probe as directed, using the Breakout Box. 6:1

40
20
000000000031
0000000000
300000000000
100000000000
21
1
IIlo..
11

ALL RIGHTS RESERVED
3.0L
EFI

'3 150 DG/W Vehicle Speed Sensor (+) VSS DIF (+)
4 648 R/LB Ignition Diagnostic Monitor (California only) IDM
Ignition Diagnostic Monitor (49 States &
4 11 DG/Y 10M
Canada)
8 787 PK/BK Fuel Pump Monitor (California only) FPM
Data Communications Link (-) (California
9 915 PK/LB
only)
DATA (-)
10 585 P AIC Cycling Switch (with heated Windshield) ACCS

10 883 PK/LB AIC Cycling Switch (w/o heated W.indshield) ACCS
13 144 DIY Vehicle Speed Control Solenoid SOL (+)
17 201 T/R Self-Test Outputl"Check Engine" Light STO/MIL
18 315 DG/P Transmission 413 Switch THS 4/3
19 237 O/Y Transmission 3/2 Switch THS 3/2
21 68 O/BK Idle Speed Control - Bypass Air ISC-BPA
23 310 Y/R Knock Sensor (49 States & Canada) KS
27 352 BR/LG Pressure Feedback EGR (California only) PFE
Data Communications Link (+) (California
28 914 TID DATA (+)
only)
30 480 PlY Neutral Pressure Switch NPS
EGR Vacuum Regulator Solenoid (California
33 360 DG
only)
EVR

35 146 W/PK Speed Control Vent Solenoid SCVNT
(Continued)

ALL RIGHTS RESERVED
EECIV - Engine Supplement -- Passenger Car 15..35
3.0L
~EC~IV Module Connector Pin Usage EFI

42 145 GY/BK Speed Control Vacuum Solenoid SCVAC
46 359 BK/W Signal Return Ground . SIG RTN
48 200 W/BK Self Test Input STI
49 89 0 HEGO GND
Ground
53 224 T/LB Lock-Up Solenoid (Transmission) LUS
54 331 R Wide Open Throttle (WOT) AIC Cut Off WAC
55 197 T/O Electro Drive Fan (Low) EDF
59 96 T/O Injector Bank 2 . INJ Bank 2

-
6~r000000000051 @OOOOOOOOOOO
0
- 141
directed, using the Breakout Box. 20 0000000000" 100000000000 1

ALL RIGHTS RESERVED
~
...::s CfI
w
G)
rt'"
FPM
8
J INERTII
;-
-, S~TQ
ae-
CQ
,I\. 12
~
If' '"'I
---
FUEl
FP
, 18 .....L ~ PUMP
22 IIWIIW
~
24
~~~~ ~
VPWR
, RELAY
on
"-
37
T
57
VPWR EEC
POWER
-,
rn
8
,
.... RELAY
L.,
I
::s
...or+
I
IGNITION VOLTAGE
.-l-.
' WllIIIN
SWITCH
r--
INVERTER
I I---
...... T .....
6OPIN
BATTERY START/RUN
I..--..e ,
.... 13 i
,
.....
...
204060
L_t _J ~
A A
'Y
r
,
~
2 1 ~CC
1---'I EDF
-.,
~
"-
1
3
I'
r C/)
14 ! RELAY ......l- 4 n
=-
EDF ....
55 , 1L _ _1-!
,L
VVVVVY
..;.._J "COOLING
T L....--
-. FAN ~
~
~
,
6
7
VOLTAGE
INVERTER
1 -
.,-
........
":: a
C
HEDF
RELAY .......L
I
I
....r+ rn
rn
-- n
HEDF .... 17
52
CYCLIC
WllUIIII oI
NC OEM,
SWITCH
...---............
PRESSURE
SWITCH
.~
T
,.... 21 --
SOLID
23 I.....
I'
<:
I
1
10
ACCS
.... 22
STATE rn
;:,
1 21 41 54
'tJ..AC , RELAY
co
15 "--- AIC
CLUTCH I
~ S'
" COIL
~ 16 r ~
CD
I " 1 tJ)
C
"0
"0
CD
3
-I
CD
::J
~
S
en
ALL RIGHTS RESERVED
rn ~ en
A9354E
... r-
."

C>
CD
::J
co
...
CD
oS
...
m
m
o
50 FPM I I a..
(\)
<:
I
m
ca ~
5"
FUEL
~~ c
...
m
,,'" '>I" I~ 1- ;-
~
g'
~
"2.
VPWR
: : VeWR T 1 24
:~~ER RECAV
- . . . . .
n
o
~
~
60 PIN I --......
BATIERY I I_.. T" I
STAR IRUN r INVERTER
- - -. I ~ I I I I I 0
=
I I'".....
-I
"0
I
20 40 60 ~ \. \. 13 ..r---1 . .....
fI)
fI)
..... m
LOW
SPEED I 1 /\I" I'\ 1 2 I ~ _I I - I- 3 / I.
/ VBAT II ft)
... ~m
55 EDF I 1 I \.1 \ 14 ,S ,r--1: RELAY I I I 1 I 1I 4 J" I (IJ;;
n e:
SP~~D I \I\ F; INVERTER ' . . ' I II I I I ;
COOLING ' ~ ~)'&.
.
1
HEDF I I I I .-I I I I ~
FAN 'I: 17 RELAY I
.....
.,
NC. OEM
SWITCH
PRESSURE
SWITCH
I ~. ..
I AIC
CLUTCH
I I n
10 ACCS ~ ) 21 SOLID
STATE
1 21 41 54 WAC \ \ 22 RELAY

m~
A13612A
.,.,c:>
ALL RIGHTS RESERVED
--r- ..
UI
W
......
3.0L
Integrated Controller Pin Usage
EFI
Pin Circuit Color Applications Abbreviations
1 181 BRIO Power to EDF Relay PT/EDF
1 181 BRIO Power to Cooling Fan (Probe Only) PTF
2 181 BRIO Power to EDF Relay PT/EDF
2 181 BRIO Power to Cooling Fan (Probe Only) PTF
3 228 BR/Y Power to Cooling Fan PTF
3 228 BR/Y Power to Fan Relays (Probe Only) PTR
4 228 BR/Y Power to Cooling Fan PTF
4 228 BR/Y Power to Fan Relays (Probe Only) PTR
5 787 PK/BK Power to Fuel Pump PTP
6 38 BK/O Power to HEDF Relay PT/HEDF
6 38 BK/O Power to Cooling Fan (Probe Only) PTF
7 38 BK/O Power to HEDF Relay PT/HEDF
7 38 BK/O Power to Cooling Fan (Probe Only) PTF
8 37 Y Battery to EEC Relay BATT (+)
12 38 BK/O Power to WOT A/C Cut Off PT/WAC
13 16 R/LG Key Power KEY PWR
14 197 T/O EDF Circuit EDF
15 60 BK/LG Power Ground PWR GRD
16 57 BK A/C Clutch Ground PWR GRD
21 883 PK/LB A/C Cyclic Switch ACCS
22 331 R WOT A/C Cut Off WAC
23 347 BK/Y Power to A/C PTAC

ALL RIGHTS RESERVED
3.0L
EFI
11 orc ~ System PASS ".
13 r ~ Cannot control rpm d~rjng Self-Test low rpm check
15 c ~ Keep Alive Memory (KAM) test failure
21. or ~ ECT sensor input is out of Self-Test range
22 orc ~ MAP sensor input is' out of Self-Test range
23 or ~ TP sensor input is out of Self-Test range -
25 r ~ KS sensor signal is not sensed during Dynamic Response Test
29 c ~ Insufficient input from the Vehicle"Speed Sensor (VSS)
33 rc ~ EGR valve opening (PFE) not detected
35 orc ~ PFE circuit" is above maximum voltage
39 c ~ AXOD lock-up failed
52 r ~ PSPS always staying open or closed
57 c ~ AXOD Neutral Pressure Switch (NPS) circuit failed open
59 c ~ AXOD 4/3 pressure switch circuit failed open
61 oc ~ ECl sensor circuit grounded
62 0 ~ AXOD 4/3 or 3/2 pressure switch circuit grounded
67 0 ~ Neutral Pressure Switch (NPS) circuit closed; A/C ON
72 r ~ Insufficient MAP output change during Dynamic Response Test
(Continued)

ALL RIGHTS RESERVED
15-40 EECIV - Engine Supplement - Passenger. Car
3.0L
EFI
88 0 ~ Electro-drive fan (EDF) circuit failure
89 a ~ Lock-Up Solenoid (LUS) circuit failure
96 oc ~ Fuel pump circuit open/Battery to ECA
NO CODES ~ Unable to initiate Self-Test or unable to output Self-Test _codes
CODES NOT LISTED ~ Service codes displayed are not applicable to the vehicl~ being tested

ALL RIGHTS RESERVED
-I m
~ m
c n
LH HEATED RH HEATED ENGINE POWER :u :<
EXHAUST EXHAUST COOLANT STEERING THROTTLE
:E~~~ T~~;~~R ~~~sEJ:~C ~~~~:~~

MASS VEHICLE
cfI) fTJ
.....
t,
GAS OXYGEN GAS OXYGEN TEMPERATURE PRESSURE POSITION AIR FLOW SPEED
HEGO SENSOR
GROUND (HEGO-F)
SENSOR
(HEGO-R)
OCTANE SENSOR
ADJUST (ECT)
SWITCH
(PSPS)
SENSOR
(TIP) (KS) (ACT)
CLUTCH
SWITCH SENSOR (BP) EGR (PFE)
SENSOR
(MAF)
SENSOR
(VSS)
SELF-TEST
~
I
rw
CONNECTOR
'Us'~;;:c~"! Q ~~ ~~ ~ ~ ,. ~
lfo~
il ..;. , ~:>-~ ~'T-t0--~:./j~~-----.~22-
. 0 ~ :, /, SELFTEST a
......-.
m
::s
co
~
CLUTCH INTERLOCK
~
MAF
SWITCH
CLUTCH ENGAGE
SWITCH
m~TA~
(
POWER
GND
POWER
GNO
IGNITION18 46
RUN
CIRCUIT

7
46
46
46
I 23
46
25
46 30 46
45
0
26
27
46
26 I
9 50 40/60
37/57
3 6'
L . 46
0
17
INPUT
(STI)
~
46
n
.....
DJ
5"
CD
en
c
~
~
KS I -:- "CHECK ~
n
9 MAFRTN E~~I~r CI) ii
3 VSS DIF ( + ) ~........
n 3
-I
PSPS
2
VSS DIF (-)
6 HEGOGRD
f~
lFl :r CD
::s
G HEGOF I ~
60 PIN
a HEGO-R
~
~
~
7
CES
O~A~
E~
m
~
IGNITION
RUN
a
DJ
"U
I
en
en
20 40 60
C
TP
...-.
fII+ CD
A~
n ::s
..n
H
~
BP
PFE;
co
V CD
VREF
~
..
SIGRTN
~
Sm/MIL
v STI I
a
~
CID CAMSHAFT
r--1:L1
10M SENSOR
gi
4
U a....- mSHIFT INDICAmR LAMP I I ~ 59~ 1~
~
~
~:;OUT ' .-~----:-
,
D
4 (5'~ '--56~' I
" ' , ~ ~
re IQN GND
~
CASE GNP
-INJ3 ~
- - t::::!:O
- - -

1~
f
D DIS
CONNECTOR
D CRANKSHAFT
1':FN=R
. -24
~
5
5_ :~~:~ ~: ~~
INJECTO~RS~
a, INJ-4
INJ-5
I
w. IN I""
12141 m
3
:t:W
I I
~
i
3 13 14 15 37/57
3
2
.~ 1 f r r m IGNITION
SW~
1
3 VPWR I 3? 1 32
5
VPWR s~i: 0 ~ ,~ ~ \Pif+t---t+----J
C~YNp~~~L VA~~~M ~~~~R C~~L1NG :: ~ ~ CL~icH
19 FPM
34 DOl
AIR
(ISCBPA)
REGULAmR
m TRIPMINDER
. i':VRI
SOLENOID
ICANPI
IN!tIR
CONTROL
SOlENOID -dJ m
m FUEL PUMP
~~I~~~
I
L '9
I
f-. ~
~ is
7 " 9 ' ~~
22
t (-)
3
KAPWR
4 PWR GND
60 PWRGND
. . MESSAGE CENTER -
BAnERY
1.10HM
1 r::
... '0
40/60 (+)
54 WAC \\\-1"-"11
10 ACCS
BAn. ~ " -------..
NC OEM CYCLIC
10 I f-. a+tH-+t+-+-+--'
~
\224
'v--
50
f
SWITCH PRESSURE
EDF SWITCH
LOW FUEL PUMP RELAY
FIIFI PlIMP RFLAY
1<1n.1<
Cl)CI)rA
ALL RIGHTS RESERVED
fTJ:C
412787-8
""0=
... r-- ~
U'I

".
~
3.0L
EEC-IV Module Connector Pin Usage SHO
SEFI
4 395 GY/O Ignition Diagnostic Monitor 10M
9 968 T/LB Mass Air Signal Return MAF RTN
10 883 PK/LB A/C Clutch Signal ACCS
12 557 BR/Y Injector #3 INJ 3
13 558 BR/LB Injector #4 INJ 4
14 559 T/LB Injector #5 INJ 5
15 560 LG Injector #6 INJ 6
17 201 T/R Self-Test Outputl"Check Engine Light" STO/MIL
18 929 PK Octane Adjust OCT ADJ
21 68 O/BK Idle Speed Control Bypass Air ISC
22 97 T/LG Low Fuel Pump Relay LFP
24 795 DG Cylinder Identification Sensor CID
29 94 DG/P Heated Exhaust Gas Oxygen - Rear HEGO-R
(Continued)

ALL RIGHTS RESERVED
EECIV - Engine Supplement -Passenger Car 1543
3.0L
EEC-IV Module Connector Pin Usage SHO
SEFI
30 480 PlY Clutch Switch CES
32 965 LG/p Intake Air Control Solenoid lAC
33 360 DG EGR Valve Regulator EVR
35 146 W/PK Speed Control Vent (Solenoid) SCVNT
41 926 LB/O High Fuel Pump Relay HFP
43 90 DB/LG Heated Exhaust Gas Oxygen - Front HEGO-F
45 358 LG/BK Barometric Absolute Pressure BAP
49 89 0 Heated EGO Sensor Ground HEGO GND
50 967 DB/O Mass Air Flow Sensor MAF
54 331 R Wide Open Throttle A/C Cutoff WAC
55 197 TID Electro-Drive Fan EDF
58 555 T Injector #1 INJ 1
59 556 W Injector #2 INJ 2

connector with DVOM probe will result in permanent oaf -
0000000000" @OOOOOOOOOOO
- ~ 41
damage to the pin connectors. Always probe as 40 000000000031 0
300000000000 21
directed, using the Breakout Box. 20 0000000000 100000000000 1
11

ALL RIGHTS RESERVED
..Y'
.... ..
:s
i ~I
. I
I
i
tQ
I
a FPM
~VPWR ;1
1.1 I\.
\1..10
IDLE FUEL
PUMPRELAV
5
INERTIA
SWITCH ic.
t
-"yy-
J
~
22~
41~
J\.18
~1..t1
HIOHIFUEL
PUMPIRElAV'
...... i ..
I
I FUEL
PUMP
I
I
n
o
~
L..--
-!- :s
800PlN
204080
37~
57~ 1
:,1.. 24
a
r---
:-...........-.
,
a
......
IONrTlON
SWITCH
I
...
ft)
STARTIRUN ,- - - - -l CI'J
4----:.=.~-----~
~
a-
ft)
, .......
_
GO
3
a
55 EDF
cvcuc . ~"".-:;- an rn
rn
o
AIC DEM. PRESSURE
SWITCH SWITCH :<
lO
AoCCS BATT +....--............ SOLID
23
I
1 21 41
54WN;;
~
~ 15
...l 18
22
T ~
~t~
! ~CHi
+
rn
~
co
s-
CD
I en
c
"C
"C
i'
3
-
CD
~
I
CI'J(I)rA
"
C

ALL RIGHTS RESERVED
tTl:x
CONTROlLER HARNESS CONNECTOR CONTROlLER MODULE CONNECTOR CD
~
~O= co
A12788-8
.. r- CD
~
o
D)
~
3.0L
Integrated Controller Pin Usage SHO
SEFI
1 38 BK/O Power to EDF Relay PT/EDF
2 38 BK/O Power to EDF Relay PT/EDF
3 181 BRIO Power to Cooling Fan PTF
4 181 BRIO Power to Cooling Fan PTF
8 37 Y Battery to EEC Relay BAIT (+)
10 922 W/R Power to Low Fuel Pump Relay PT/LFP
11 926 LB/O High Fuel Pump H/FP
12 38 BK/O Power to WOT AI C Cut Off PT/WAC
13 16 R/LG Key Power- KEY PWR
14 197 TIO EDF Circuit EDF
15 57 BK Power Ground PWR GRD
16 57 BK AIC Clutch Ground PWR GRD
18 97 T/LG Low Fuel Pump L/FP
21 883 PK/LB AIC Cyclic Switch ACCS
22 331 R WOT AIC Cut Off WAC
23 347 BK/Y Power to AIC PTAC

ALL RIGHTS RESERVED
15-46 EECIV - Engine Supplement - Passenger Car
3.0L
Quick Test Codes and Code Definitions SHO
SEFI
......
11 orc System PASS
12 r Unable to control rpm during Self-Test high rpm check
13
14
r
c ... Unable to control rpm during Self-Test low rpm check
PIP circuit failure
15
15
0
c .... ECA ROM test failure
.....
18 r SPOUT circuit open
18 c 10M circuit failure SPOUT circuit grounded
19 c CID circuit failed
21
22
or
oc .... ECT sensor out of Self-Test range
BP sensor .out of Self-Test range
23
24
or
or .... TP sensor out of Self-Test range
ACT sensor out of Self-Test range
25
26
r
or ... KS sensor not sensed during Dynamic Response Test
MAF sensor out of Self-Test range
29
31
c
orc .... Insufficient input from Vehicle Speed Sensor (VSS)
PFE circuit below minimum voltage
.....
32 rc PFE circuit voltage low
33 rc EGR valve opening not detected
34 0 PFE sensor voltage out of range
.....
34 rc Exhaust back pressure high/PFE circuit voltage high
35 orc PFE circuit above maximum voltage
41 r HEGO sensor circuit indicates system lean (rear HEGO)
...
41 c No HEGO switching detected (rear HEGO)
42 r HEGO sensor circuit indicates system rich (right HEGO)
45
46
c
c .... Coil 1 primary circuit failure
Coil 2 primary circuit failure
.....
48 c Coil 3 primary circuit failure
49 c . SPOUT signal defaulted to 10 degrees BTDC/SPOUT circuit open
51 oc ECT sensor indicated 254F I circuit grounded
.....
52 0 PSPS circuit is open
52 r PSPS circuit did not change states
53 oc TP sensor circuit above maximum voltage
.....
54 oc ACT sensor indicates - 40F/circuit open
56 oc MAF sensor input is greater than maximum voltage
59 oc Low speed fuel pump circuit open (battery to ECA)
61
63
oc
oc ... ECT sensor indicated 254F/circuit grounded
TP sensor circuit below minimum voltage
...
64 oc' ACT indicated 254F/circuit grounded
66 c MAF sensor input is less than minimum voltage
67 0 Neutral Pressure Switch (NPS) circuit closed; A/C ON
(Continued)

ALL RIGHTS RESERVED
3.0L
Quick Test Codes and Code Definitions SHO
SEFI
72 r ~ Insufficient MAF output change during Dynamic Response Test
79 0 ~ A/e on/Defrost on during Self-Test
81 0 ~ lAS circuit failure
83 oc ~ Low speed primary fuel pump circuit failure
88 0 ~ Electro-Drive Fan (EDF) circuit failure
91 r ~ HEGO sensor indicates system lean (front - HEGO)
91 c ~ No HEGO switching detected (front - HEGO)
92 r ~ HEGO sensor indicates system rich (front - HEGO)
96 oc ~ High speed fuel pump circuit open

ALL RIGHTS RESERVED
,.6
(II
LH HEATED
EXHAUST
GAS OXYGEN
HEATED
EXHAUST
GAS OXYGEN

~
CD
....rn
SENSOR SENSOR ENGINE MANIFOLD POWER
(HEGOF) (HEGO-A) COOLANT THROTTLE ABSOLUTE STEERING VEHICLE
TEMP POSITION PRESSURE PRESSURE PRESSURE SPEED SPEED
SENSOR SENSOR FEEDBACK SENSOR SWITCH CONTROL SENSOR SELF-TEST
(ECT) EGR (PFEj (MAPj (PSPSj COM SW (VSSj VBATT + CONNECTOR
~
IGN~ON ~
RUN
TEST
INPUT ...~
....
L....-_--.-<I+-.. (STI)
n
~ 'l6
....
C
(I)
"_c, I r n
HEGOR
9 ECT
7i'P
ENGINE~ TO
:r
~
a
LIGHT
7 ACT (TAURUSI IGNITION
20 40 60 RUN
5- SABLE
an....
MAP
ONLY)
5 PFE
~ VREF TO INSTRUMENT ( . - . -
PANEL ~4 I I I
2 PSPS
".. "' ' ' ' ' ' " ii

SIG RTN
17SIL.- --- 59
..
16 G'
PIP G'D - _---
_. '" ". " '
H
56 SPOUT :
36 CASEGND
'" :~~3 l- ~4
, ~ ~
'"",croRS'
',,,,, ~
i~) ~~ ")~~
4 IGNITION
rn
rn
1 21 41
o
DATA
B FP [+) ~ I I
I' , ;:
44
~~ ISCBPA 33 ~1 I
rn
~
VPWR
57 PWR ::s
37
9 TTS co
:i"
CD
EGR CANISl
19
CONTROL PURGE
(EVR) (CANP)
UJ
C
53 "0
30~"""'- "0
18,U1i~.......- -
CD
50 ACL ~ AIR SUSPENSION I I I III I 3
~ n:AUWU~::~~~~~LY)
-I
IGNITION SWITCH
~
CONTROL (CONTINENTAL CD
32
34 HEQE ONLY)
::s
1 EDE
5
1 KAPWR
40~ "V
60~
(I~
I

ALL RIGHTS RESERVED
35 SCVNT
1
~,
~C at
51 SOL
"~c:;
10 WAC
54-
l..r.: C':,.....
NOTE: WIRI. .._..
(+)
~ .. v
~UI!l ~"V"_ .... __ ~ ~ __ ~ ... _ .... _
8 ,
rn~Qc
::!]cr-
CD
:s
..o
ca
CD
HARNESS CONNECTORS A11513C
..
ID
3.8L
EEC-IV Module Connector Pin Usage AXOD
SEFI
Car Lines
Taurus/Sable Continental
Pin Application Abbreviations
Wire Wire
Crt. # Crt.#"
Color Color
1 37 Y 37 Y Keep Alive Pow~r KAPWR

2 330 Y/LG 330 Y/LG Power Steering Pressure Switch PSPS
3 150 DG/W 150 DG/W Vehicle Speed Sensor (+) VSS DIF (+)
4- . 11 DG/Y 11 DG/Y Ignition Diagnostic Monitor 10M
5 .810 R/LG 810 R/LG Brake On/Off BOO
6 563 O/Y 563 O/Y Vehicle Speed Sensor (-) VSS DIF (-)
7 354 LG/Y 354 LG/Y Engine Coolant Temperature Sensor ECT
8 695 BK/O 695 . BK/O Data Communications Link (-) DATA (-)
9 854 GY/W 854 GY/W Transmission Temperature Switch TIS
10 585 P 585 P A/C Cycling Switch (w/htd. windshield) ACCS
10 883 PK/LB 348 LG/P A/C Cycling Switch (w/o htd. windshield) ACCS
11 144 O/Y 144 O/Y Vehicle Speed Control Solenoid SOL (+)
12 557 BR/Y 557 BR/Y Injector #3 INJ 3
13 558 BA/LI;3 958 BR/LB Injector #4 INJ 4
14 559 T/LB 559 T/LB Injector #5 INJ 5
15 560 LG 560 LG Injector #6 INJ 6
16 350 GY 350 GY Ignition Ground' IGN GND
17 201 T/R 201 T/A Self.;Test Outputl"CHECK ENGINE'.' Light STO/MIL
18 315 DG/P 315 DG/P Transmission 413 Switch THS 4/3
19 237 O/Y 237 O/Y Transmission 3/2 Switch THS 3/2
20 57 BK 57 BK Case Ground CASE GND
21 68 O/BK 68 O/BK Idle Speed Control -' Bypass Air ISC-BPA
22 97 T/LG 97 T/LG Fuel Pump FP
25 357 LG/P 357 LG/P Air Charge Temperature Sensor ACT
26 351 O/W 351 O/W Reference Voltage VREF
27 352 BR/LG 352 BR/LG Pressure Feedback EGR PFE
28 151 LB/BK 151 LB/BK Speed Control Command Switch SCCS
Heated Exhaust Gas Oxygen
29 90 DB/LG 90 DB/LG
Sensor - Rear
HEGO-R
30 480 PlY 480 PlY Neutral Pressure Switch NPS

31 101 GY/Y 101 GY/Y Canister Purge Solenoid CANP
32 - - 637 LG Air Suspension Control ACL
33 360 DG 360 DG EGR Vacuum Regulator Solenoid EVR
34 305 LB/PK - - Data Output Line DOL
35 146 W/PK 146 W/PK Speed Control Vent Solenoid SCVNT
(Continued)

ALL RIGHTS RESERVED
3.8L
EEC-IV Module Connector Pin Usage AXOD
SEFI
Car Lines
Taurus/Sable Continental Application Abbreviations
Pin
Crt.#: Wire Crt.#: Wire
Color Color
36 324 Y/LG 324 Y/LG Spark Output SPOUT
37 361 R 361 R Vehicle Power VPWR
39 461 0 461 0 Speed Control Command Switch Ground SCCS GND
40 60 BK/LG 60 BK/LG Power Ground PWR GND
41 639 PK 639 PK High Electro Drive Fan HEDF
43 94 DG/P 94 DG/P
Sensor - Front
HEGO-F
44 696 O/BK 696 O/BK Data Communications Link (+) DATA (+)
45 358 LG/BK 358 LG/BK Manifold Absolute Pressure Sensor MAP
46 359 BK/W 359 BK/W Signal Return Ground SIG RTN
47 355 DG/LG 355 DG/LG Throttle Position Sensor TP
48 200 W/BK 200 W/BK Self Test Input STI
49 89 0 89 0 Heated EGO Ground HEGO GND
50 787 PK/BK 787 PK/BK Fuel Pump Monitor FPM
51 145 GY/BK 145 GY/BK Speed Control Vacuum Solenoid SCVAC
53 . 224 T/LB 224 T/LB Lock-Up Solenoid (Transmission) LUS
54 331 R 331 R Wide Open Throttle (WOT) A/C Cut Off WAC
55 197 T/O 197 T/O Electro Drive Fan - Low EDF
56 349 DB 349 DB Profile Ignition Pick-Up PIP
58 555 T 555 T Injector #1 INJ 1
59 556 W 556 W Injector #:2 INJ 2

-
60 '000000000051 500000000000
- 41
damage to the pin connectors. Always probe as 40 000000000031@300000000000 21
directed, using the Breakout Box. 20 0000000000 11 100000000000 1

ALL RIGHTS RESERVED
A11514C C/)~~
lTJO~
ALL RIGHTS RESERVED
::!]Cr- .....
en

en
.....
3.8L
Integrated Controller Pin Usage AXOn
SEFI
1 181 BRIO Power to EDF Cooling Fan PT/EDF
2 181 BRIO Power to EDF Cooling Fan PT/EDF
3 38 BK/O Power to Cooling Fan Relay PTF
4 38 SKID Power to Cooling Fan Relay PTF
6 228 BR/Y Power to HEDF Cooling Fan PT/HEDF
7 228 SR/Y Power to HEDF Cooling Fan PT/HEDF
8 37 Y Battery to EEC Cooling Fan BATT (-)
12 38 BK/O Power to WOT A/C Cut Off PT/WAC
14 197 TID EDF Circuit EDF
16 321 GY/W AIC Clutch Ground PWR GAD
21 348 LG/P A/C Cyclic Switch ACCS
22 331 R WOT A/C Cut Off WAC
23 347 BK/Y Power to A/C PTAC
24 361 R Vehicle Power VPWA

ALL RIGHTS RESERVED
3.8L
Quick Test Codes and Code Definitions AXOD
SEFI
11 orc ~ System. PASS
15 c ~ Keep Alive Memory (KAM) test failed
18 c ~ 10M circuit failure/SPOUT. circuit grounded
23 or ~ TP sensor input is out of Self-Test range
29 c ~ Insufficient input from the Vehicle Speed Sensor (VSS).
32 rc ~ PFE circuit voltage is low
33 rc ~ EGR valve opening (PFE) is not detected
39 c ~ AXOD lock-up failed
41 r ~ HEGO sensor circuit indicates system lean (right HEGO)
41 c ~ No HEGO switching detected (right HEGO)
42 r ~ HEGO sensor circuit indicates system rich (right HEGO)
52 r ~ PSPS always staying open or closed
57 c ~ AXOD Neutral Pressure Switch (NPS) circuit failed open
59 0 ~ AXOD 4/3 pressure switch circuit failed closed
61 oc ~ ECT sensor circuit grounded
67 0 ~ AXOD Neutral Pressure Switch (NPS) circuit failed closed/A/C ON
68 orc ~ AXOD Transmission Temperature Switch (TIS) failed open
69 0 ~ AXOD 3/2 pressure switch circuit failed closed
(Continued)

ALL RIGHTS RESERVED
15-54 EEC-IV - Engine Supplement - Passenger' Car
3.8L
Quick Test Codes and Code Definitions AXOD
SEFI
70 c ~ ECA data communications link (DCl) circuit failure
71 c ~ Cluster Control Assembly (CCA) circuit failed
72 c ~ Message Center Control Assembly (MCCA) circuit failed
79 0 ~ A/C on/Defrost on during Self-Test
89 0 ~ lock-Up Solenoid (lUS) circuit failure
91 r ~ HEGO sensor circuit indicates system lean (left HEGO)
91 c ~ No HEGO switching detected (left HEGO)
92 r ~ HEGO sensor circuit indicates system rich (left HEGO)
96 oc ~ Fuel pump circuit open/Battery to ECA
98 r ~ Hard fault present

ALL RIGHTS RESERVED
m
m
0I
LHHEATED AIR MANIFOLD ENGINE
<:
.....
RH HEATED
EXHAUST
GASOX'YGEN
EXHAUST GAS THROTTLE CHARGE ABSOLUTE COOLANT SPEED VEHICLE
tTl
OX'YGEN POSITION TEMP PRESSURE PRESSURE TEMP CONTROL
SPEED SELF-TEST
I
S~;S~R ~CONNECTOR
HEGO SENSOR SENSOR' SENSOR SENSOR FEEDBACK SENSOR SENSOR COM. SN.
~
IGN. START
GROUND (HEGOl (TP) (ACT) EGR (PFE) (MAP) (ECT) (SCCS)
SWITCH (HEGO)
m
BATT 22
n....
I"~
t
STARTE~~l ~ ~o & ,,~~~~ I~
.N(:T~
~
30 NOS
o SELF-TEST
...
.-.
CO
5"
-=--
RELAY
49 POWER IGNITION P01E:rGNitloN .riIJ BRAKE
T n
s:
CD
en
5~
28~
39 ~~~~
SGND
I GND 43 RUN
I
GND 29 RUN 26
I
':" 63
5 -=-
LIGHT 46
I 8 44 17 48
..... c
~
EEC,IV
6
VSS DIF (-)
VSS DIFF (.)
I
I IJ en
~
CD
MODULE
3
HEGO GND I "CHECK
n 3
-I
49
CI
:r
HEGO-L ENGINE"
60-PIN 43
HEGO-R LIGHT ~
29 (MIL)
~
20 40 60 ECT
7
47
25
TP
ACT BATT(+) TO a
s:
."
45 MAP
.....-. I
AFTER IGNITION
27 PFE
HORN RELAY RUN en
26 VREF
en
CI
46 SIG RTN
n ~
17 5TO & MIL
44
8
DATA-
DATA + ..
co
CI
48~
2:~* 22~,..M_S
10 IGNITION COIL (-)
"';"'_~ ~
10 IGNITION RUN
I ..
0
I
10 IGNITION START . TFI

36 SPOUT ,,,- - -- "?', m=J36 ,"i--=r, HARNESS
16 IGN GND I 'I (\u...r-- i Q----,-, CONNEClOR
56 PIP \ I \ j
12_
IN_J_3 '~---------
1 21 41
59~
58.!!':!:L!
13~
14~
15 INJ6
31~
33~ lal
ZC1.
C>ii:
22~ 37/57
21 ISC
37~
57 VPWR
37/57 ,

39~O
22
'51 0
EGR -11 0
VACUUM PURGE OlSTRIBU1ORHALL
REGULATOR (CANP) HARNESSCONNEClOR VEHICLE
(EVR) SPEED CONTROL
Y~L .. TO TRIPMINDER MESSAGE CENTER
run 'aI'!U
I I I I 40/60
BATT. "- A11S31-C

en~~
ALL RIGHTS RESERVED
WAC
NC
OEM
CYCLIC
PRESSURE
RELAY
tTlc:ac
SW SW
::!]or- ....
U1
I
U1
U1
3.8L
EEC-IV Module Connector Pin Usage RWD
SEFI
5 511 LG Brake On/Off BOO
6 359 BK/W Vehicle Speed Sensor (-) VSS DIF (-)
8 696 O/BK Data Communications Link (-) DATA (-)
10 883 PK/LB A/C Cycling Switch ACCS
Self-Test Output and "Check Engine"
17 382 Y/BK STO/MIL
Light
21 69 R/LG Idle Speed Control - Bypass Air ISC- BPA
25 357 LG/P Air Charge Temperature ACT
29 96 T/O HEGO-R
Sensor - Right
30 32 R/LB Neutral Drive Switch NDS
33 360 DG EGR Vacuum Regulator EVR
39 57 BK Speed Control Ground SCGND
(Continued)

ALL RIGHTS RESERVED
3.8L
EEC-IV Module Connector Pin Usage RWD
SEFI
43 95 T/R HEGO- L
Sensor - Left
44 695 BK/O Data Communications Link (+) DATA (+)
45 356 DB/LG Manifold Absolute Pressure Sensor MAP
46 359 BK/W Signal Return SIG/RTN
49 89 0 HEGO G
Ground
51 145 GY/BK Speed Control Vacuum Solenoid SCVAC
58 555 T Injector #1 INJ 1

... -
60r00000000005' @OOOOOOOOOOO .... 41
directed, using the Breakout Box. 20 0 000000 000 1 10 0 00 00 000 0 0 1
lio..
1
....
ALL RIGHTS RESERVED
3.8L
Quick Test Codes and Code Definitions RWD
SEFI
18 c ~ IDM circuit failure/SPOUT circuit grounded
22 orc ~ MAP out of Self-Test range
33 rc ~ EGR valve opening NOT detected
34 rc ~ Exhaust pressure high/PFE circuit voltage high
41 c ~ No HEGO switch detected (right HEGO)
51 oc ~ ECT indicated - 40F/ circuit open
54 oc ~ .ACT indicated - 40F/circuit open
67 0 ~ Neutral Drive Switch (NDS) circuit open
91 r ~ HEGO sensor circuit indicates system lean (left HEGO)
92 r ~ HEGO sensor circuit indicates system rich (left HEGO)

ALL RIGHTS RESERVED
-I In
:::I: In
C 0
IGN. START SW.
-30
~
~.
M
NEUTRAL
DRIVE
SWITCH
STARTER
HEGO
LH HEATED RH HEATED
EXHAUST
SENSOR
a
(HEGO)
EXHAUST
GROUND GAS OXYGEN GAS OXYGEN KNOCK
SENSOR
(HEGO)
ENGINE
COOLANT
THROTTLE
POSITION AIR CHARGE
SENSOR TEMP SENSOR SENSOR TEMP SENSOR
(KS) (ECT)
OCTANE
ADJUST PRESSURE FEEDBACK
fTPI.(ACT)SWITCHSENSOR(BP)EGR(PFE)(MAF)(VSS)
~,
MASS
BAROMETRIC PRESSURE AIR FLOW
SENSOR
VEHICLE
SPEED
SENSOR
~
z
c
m
:II
!!!
-
rn
~
0-
<
m
I
:::J
co
flJi\\ =~ ~
f , . <'~ ~ ~rr=ID1 ~., ~.
~, ! 01:1 . ",,-\ :II
M RELAY ,
c :!. SO
CD
.......
n
~.. ~".. i ]_1 l t r II Tlj r1
,
0
0
c:
~
:II
-
S
(I)
n
en
C
"0
"0
CD
3
50 MM.
9~~~~~(+)
130CTADJ
8 VSS DIF (-)
4: HEGOGND
~
fTO
=-
~
a
-
CD
:::J
I
'1J
I
~PIN
204080
43 !:!EQQ.h.
29~1
; TP
'~
IGNITION
RUN
....
S (II
(II
CD
25 n :::J
co
23~
452 7::E- - I I I I I I I I I I I' ...
CD
26~
0
4 mm:.t:! ...I
-
,: !ilQlMIL
46~
. '" .
~!h.
L" ~--- _.
24 10
POUT
38 IGN GND
rn""""'' ' '
I"""",,
I
.,-.-------~
(~.
"
I
, ~' (:.
,t
CAM SENSOR
TOOlS
L.--..,.
IGNITION RUN
CIRCUIT
TO SHIFT INDICATOR
H
~~..
.--12
I
- - - - - _22_
~~ ~ . LAMP
12 iNJ.2
I~~'"''
59 iNJ.i 2 INJECTORS 6
1 21 41 56 iNJ.4 FUEL PUMP
14 INJ.5 I I i RELAY
:~ iNJ.6
CANP 31 I
31 EVR
33;p- 33-
22iSC
2 1 V'PWR
~
37 V'PWA J IDLE
57--
SPEED
CONTROL
BYPASS
AIR EGR CANISTER
" ". IISC-BPA) V"""" ,"'G' ,-,
, KAPWR I REGULATOR SOLENOID
~
"M w<O
..eo"
,., "''' '"'''' """ ow'",
NO
,.,
~~CE
:=======_.. . -=========~l
10 ACCS
41
I ~ 10 1 - ..
--========----=.-----==============j
55 ECE BATT .......-" - - - - BATTERY
AlC OEM CYCLIC
(I)(I)CJ:J
I. = m~Qo
ALL RIGHTS RESERVED
SWITCH r>RESSURE
SWITCH -
A11S1SC
~\ Jr- ...
U'I

U'I
CD
3.8L
EEC-IV Module Connector Pin Usage SC
SEFI
2 275 Y A/C Pressure Cut-Off Switch APCS
4 11 DG/Y Ignition Diagnostics Monitor IDM
6 359 BK/W Vehicle Speed Sensor (-) VSS DIF (-)
7 354 LG(Y Engine Coolant Temperature Sensor ECT
9 968 T/LB Mass Air Signal Return MAFRTN
16 796 LB Ignition Ground IGN GND
17 382 Y/BK Self-Test Outputl"Check Engine Light" STO
18 359 BK/W Octane Adjust OCTADJ
21 69 R/LG Idle Speed Control ISC
24 795 DG Cylinder Identification Sensor CID
29 96 T/O HEGO-R
Sensor - Right
30 32 R/LB Neutral Drive Switch NDS
32 836 O/W Air Suspension Control ACL
(Continued)

ALL RIGHTS RESERVED
EECIV - Engine Supple~ent - Passenger Car 1561
3.8L
EEC-IV Module Connector Pin Usage SC
SEFI
39 465 W/LB Speed Control Command Switch Ground SC GND
43 95 T/R Heated Exhaust Gas Oxygen Sensor - Left HEGO-L
45 356 DB/LG Barometric Pressure Sensor BP
46 359 BK/W Signal Return Ground SIG RTN
49 89 0 HEGO Sensor Ground HEGO GND
53 462 P Shift Indicator Light SIL
54 331 R Wide Open Throttle AIC Cut Off WAC
55 197 TIO Electro-Drive Fan EDF
56 349 DB Profile Ignition Pick-up PIP
58 555 T Injector # 1 INJ 1
Pin locations given for reference only. Probing 60 pi'n

- -
6:f000000000051 @OOOOOOOOOOO
0
41
directed, using the Breakout Box. 20 .... 0000000000 11 100000000000 1

ALL RIGHTS RESERVED
.....
'"en
.... N
a
~
-3 r
VPWR
T
"
~
24 =...
5 ,VPWR
., I C
~
rn ~
8
1~
I
I
I
Q..
IGNITION ---.A.-
vvvvw
-- ---.,' E~ T T1 ~
SWITCH
6O-PIN
BATTERY STARTIRUN
.. 13
: POWER
RELAY
...
t ..
20 40 60 L-......e ~
1
I } i
l______, :s
~
f~ ~ a......
PRIMARY
FAN
,
-----,
RELAY 3/v
-
EDF
,"
""'I'
avcc I
L
!
"
L4~ ~ J VBi (T
55
LOW
SPEED
14
I
,-_ _f __J
I
1
vvvvvv
. I ...
~
~
T
... 8
SECONDARY
FAN
~
en
n
~ 7 1 RELAY ......
HIGH -4 / : :r
SPEED
I I
~
L
a
HEDF COOLING FAN 17
41 . VVVUUII
I < 12
~
AlCOEM.
SWITCH
CYCLIC
PRESSURE I C
ACCS
BATT +.....-..-.~
SWITCH
...
1
," 21
SOLID
23
"
I'
...n.
~ m
m
o
10
WAC .. STATE
4~
;:
22
1 21 41 54
7
RELAY +
AlC
g~
7
...
,.
....
15
16 T .:L.- * CLUTCH
COIL I
m
I :J
co
S'
NOTE: FUEL PUMP RELAY LOCATED IN. REAR OF VEHICLE. CD
en
c
""CD
3
-
CD
:J
CONTROLLER MODULE CONNECTOR CONTROLLER MODULE CONNECTOR

I
"1J
A13588-A D)
en
ALL RIGHTS RESERVED
entrJ~ (I)
CD
m~Qo :J
:!1 \ r-e
J ..o
co
CD
..
D)
3.8L
Integrated Controller Pin Usage SC
SEFI
1 228 BA/Y Low Speed Fan PT/EDF
2 228 BA/Y Low Speed Fan PT/EDF
3 038 BK/O Vehicle Power PTF
4 038 BK/O Vehicle Power PTF
6 181 BAlD High Speed Fan PT/HEDF
7 181 BRIO High Speed Fan PT/HEDF
8 37 Y Battery to EEC Aelay BATT (+)
12 175 BK/Y Power to WOT A/C Cut Off PT/WAC
14 197 TID EDF Circuit EDF
15 57 BK Power Ground PWA GAD
16 321 W/P A/C Clutch Ground PWA GAD
21 . 883 PK/LB A/C Cyclic Switch ACCS
22 331 A WOT A/C Cut Off WAC
23 347 BK/Y Power to A/C Clutch Coil PTAC

ALL RIGHTS RESERVED
3.8L
Quick Test Codes and Code Definitions SC
SEFI
12 r ~ Unable to control rpm during Self-Test high rpm check
13 r ~ Unable to control rpm during Self-Test low rpm check
14 c -~ PIP circuit failure
18 c ~ IDM circuit failure/SPOUT circuit grounded
19 c ~ CID circuit failed
22 oc ~ BP sensor out of Self-Test range
23 or ~ TP sensor out of Self-Test range
24 or ~ ACT sensor out of Self-Test range-
25 r ~ KS sensor not sensed during Dynamic Response Test
26 or ~ MAF sensor out of Self-Test range
34 rc ~ Exhaust back pressure high/PFE circuit voltage high
41 c ~ No HEGO switching detected (right HEGO)
49 c ~ SPOUT signal defaulted to 10 degrees BTDC/SPOUT circuit open
51 oc ~ ECT sensor indicated 254F/Circuit grounded
54 oc ~ ACT sensor indicates - 40F/Circuit open
56 oc ~ MAF sensor input is greater than maximum voltage
61 oc ~ ECT indicated 254F/Circuit grounded
64 oc ~ ACT indicated 254F/Circuit grounded
66 c ~ MAF sensor input is less than minimum voltage
67 0 ~ Neutral Drive Switch (NDS) circuit closed; A/C ON
(Continued)

ALL RIGHTS RESERVED
3.8L
Quick Test Codes and Code Definitions SC
SEFI
72 r ~ Insufficient MAF output change during Dynamic Response Test
79 0 ~ A/C on/Defrost on during Self-~est
82 0 ~ Supercharger bypass circuit failure
83 0 ~ High speed electro-drive fan circuit failure
91 r ~ HEGO sensor indicates system lean (left HEGO)
92 r ~ HEGO sensor indicates system rich (left HEGO)
96 oc ~ Fuel pump secondary circuit failure'

ALL RIGHTS RESERVED
z
RH HEATED
EXHAUST
GAS OXYGEN
ENGINE
COOLANT
THRonLE
POSITION AIR CHARGE
MANIFOLD
ABSOLUTE
EGR VALVE SPEED VEHICLE
POSITION CONTROL SPEED
0
z
I:
Im I;
SENSOR TEMP. SENSOR SENSOR TEMP SENSOR PRESSURE SENSOR COM SW SENSOR SELFTEST
~
ft)
~ ~
(HEGO) (ECT) (TP) (ACT) SENSOR (MAP) (EVP) (SCCS) (VSS) BATT + CONNECTOR 22
0
'I' ~Iq 'I' 1lf1~' ~I'~ ~,~~~~~

O SELFTEST
INPUT
0
~
oo~ :1.
~
3~ ~
(STI)
POWER
GND
POWER
GND TO I I I I I I I I Is:o r l l f
46
I 17
g
! I~I
I~ .IGNlnON =
SCCS
I II
43 29 RUN 48
0 ~
I SCCS GND
"CHECK
ENGINE"
::D
, VSS DIFF (.) LIGHT 0 (I)
; VSS DIFF 1+1 (MIL)
:E n
, BOO
; HEGO GND
TO
IGNITION
z ::r'
6OPIN
I HEGOL RUN
< ft)
a
I HEGD-R
20 40 60 ECT BAn (.)
AFTER
0
, TP
~
........
ACT HORN
MAP
RELAY 0 D
: EVP ::D
, VREF
: SIG RTN
: STO/MIL
1> n
I TI __ u "" . . . . . ,..
Q
::D

z
c
i:

::IJ
0
I I~;:
1 21 41
c
en I
I
rn
::::J
co
AlC
CLUTCH
s-
CD
RELAY BLOCK r-r-0oo-T"l
VEHICLE
HARNESS
I..__ L...t4--J "'=
POWER
en
c
CONNECTOR TO
22 I CLUTCH
"0
34 DOL _ TO TRIPMINDER "0
1 KAPWR MESSAGE CENTER
ii'
40~ 3
-I
6O~ CD
3S~ ::::J
38 SCyAC
10~
41 SOLl+l
S4 WAC I
I
,..-----------

AlC CLUTCH
TOAiC
DEMAND FUEL PUMP
"
I
II
HEATED
ALL RIGHTS RESERVED
I CYCLIC PRESSURE SWITCH PRIME PLUG

(l)c.n
: WINDSHIELD SWITCH VEHICLE HARNESS
me
:
:I Hg11~~N~~~L'EDI
L.
ONLY
.J: ~
CONNECTOR
,
A135.A
.,,=
e=-t-
n
1.
~
i: rn
~
rn
0
::D
~
rn <:
NEUTRAL LH HEATED
DRIVE
SWITCH
EXHAUST
GAS OXYGEN
RH HEATED
EXHAUST
GAS OXYGEN
ENGINE
COOLANT
THRonLE
POSITION AIR CHARGE
MANIFOLD
ABSOLUTE
EGR VALVE SPEED VEHICLE
POSITION CONTROL SPEED
~.
.....
ft) I
IGN. START SW. ~ SENSOR SENSOR rn
30 NOS t a (HEGO) (HEGO)
TEMP. SENSOR
IECT)
SENSOR
(TP)
TEMP SENSOR PRESSURE
(ACT) SENSOR (MAP)
SENSOR COM. SW SENSOR
IEVP) (seCS) (VSS) BAn.
SELF-TEST
CONNECTOR
~ ~
co
~,
~~ lF~ ~~~
~') IIJ~IJ~~~~ ~~s"'''~ ....
r1f ~ Jt~
~TER ~QQ~ lilt S"
LAY
CD
o0 I~T~7
DWER
NO
POWER
GND
TO
__ IGNITION
* ": BRAKE
LIGHT
0
n
.....
S en
c
~
~
~f
~secs RUN
"CHECK (I) CD
39 secs GND ENGINE"
n 3
-
VSS DIFF 1.\ LIGHT
_ VSS DIFF + (MIL) CD
2 BOO
TO
~ ~
ft)
49 HEGO GND
, I
a
IGNITION
43 HEGQ.L RUN
6O-PIN
~ HEGo-R "U
204060 7 ECT
47 TP
25 ACT
45 MAP
27 EVP
BATT(.)
AFTER
HORN
RELAY
an.... I
en
UJ
CD
~
co
26 VREF CD
46 SIG RTN
17 STOIMIL '"'
48 STI 0
22KOHMS D)
4 10M
, .. _ TO IGNITION COIL (-)
'"'
56 PIP , ~\ ------,-r ~
'~
~ SPOUT
16IGN GND
20 CASE GND " ..---------~
'* ":". a TFI
Iii~~~~~
~~
13 1N.J-4 CONNECTOR
12 1N.J.3
59 1N.J.2 ' 2 3 4
.~c~.
58 IN.J-l
1 21 41
14 1N.J-5
15 IN.J~
42 1N.J.7
52 1NJ.8
11 AM2
51 AMI
31 CANP
33 EVR
a
<'2 FP
~llse
37 VPWR 1
r
rk~i 11
"
57 VPWR
~
IDLE
SPEED TO
FUEL
_J CONTROL
BYPASS
AIR EGR CANISTER
PUMP ~
rreJ
IISCBPA) VACUUM PURGE AIR AIR VEHICLE
REGULATOR SOLENOID MANAG 1 MANAG 2 SPEED
M~~:~~~~~~R
rl
14 DOL (EVR) (CANP) (TAB) (TAD) CONTROL
I
,t~,"","M'
1 KAPWR
10 PWR GND EEC RELAY
;0 PWR GND 1 ~ POWER
35 seVNT
~ SCVAC TB~TTE:Y RELAY
11' SOL 1.1
TO
i4 WAC IGNITION
AlC
rnaen
10 ACCS" I SWITCH AtN40C
BAn._~~ ~l:.~~ (I)
ALL RIGHTS RESERVED
PRESSURE
--n=
SWITCH
RELAY
.... r-
SWITCH
..A.
en

....
G)
MANIFOLD
Zi: ~
CI'I
O~
..
ABSOLUTE I
G)
PRESSURE
(MAP)
Z(I) CD
IGN. START SW NEUTRAL
LH HEATED RH HEATED SENSOR MA ONLY
.i:~
(I)
m
~
DRIVE
SWITCH
G::~~~~~N G::~~~~N C~G~~T ~'6~~~~ BARQ~ETRIC E~S~~~~E~~~f~~: V~~~~~E g~~~~
~
AIR CHARGE
HEGO SENSOR SENSOR TEMP SENSOR SENSOR TEMP SENSOR PRESSURE SENSOR I SENSOR I SENSOR SWITCH SELFTEST
(I)::D ft)
a
~
~
STARTER
RELAY SENilis:~BP) rJ L:J(~~~!\ ~:~~ (I)
t
GROUND (HEGO) (HEGO) T(ECT) m(TP) (fACT) !I(E:P) (MAF) CONNECTOR
I I i,), SELFTEST ~O ~
..

I I INPUT -::D
: : (STI)
~O n
1~, " '" ~ .~, "~"~' ''''Ii ~I ! -I:E D)
. 46 46 27 50 8
OZ
q j, :E< (I)
6OPIN
20 40 60
6 VSS DIF I-I
49~
43HEGO.L
29~
7 ECT
47E.
25 ill
~
441
46
f
TO
Ze;
0-1
~O
::D~
~
.......
n
~
ft)
a
D)
IGNITION C)
45~ RUN ~
n
27~ ::D
26~ ~
46 SIG RTN Z
17 STOiMiL C
48 STI
8~
44 DATA 1+1
i:
5 BOO
~
4 10M 22K OHMS ::D
__ IGNITION RUN
"
SIL of'.I',r-
CIRCUIT 13
S3 PIP I I
C
~~
16~A~~~~D
r:y_m_-'i\~
\
._-- -----1 ~
I ( : D
D TFI
TO SHIFT INDICATOR
LAMP
'-~~ jn
m
20~
- CONNECTOR -I
13 iNJ.3
12 1NJ .
o m
o
1 21 41
S9
2
iNJ.i" INJECTORS
3
7
4
8 :E I
;:
S8iNJ.5 Z
i'NJ.6
14
1S i'NJ.7 o I
42 iNJ.8 ~ m
S2AM2" ::D :s
32 AMi CQ
37/57
38 00p
I S'
31
22
EVR"
33Fi>
1SC
VPWR
1
33
I
31
l 38
22
AlC
'
CD
en
c
"C
~
21 CLUTCH
37VPW'R
IDLE "C
S7--
SPEED
CONTROL
l.4+-1 ~ Ci
BYPASS AIR
~~,~~~
3
-
(ISCBPA) AIR AIR TO IGNITION CD
19~ MANAG 1 MANAG 2 TO FUEL.- S~~~~N :s
34 DOL _ TO TRIPMINDER (TAB) (TAD) PUMP
1 KAP'WR
40 PWR GND
MESSAGE CENTER
I
60 PW'R'GN"D
."
v:;;;:c--
m
54 en
en
~~~~
ALL RIGHTS RESERVED
10 ACCS -+t~++---_~ ....~~~g~EMAND CD

:s
..o
AlC CLUTCH FUEL PUMP 54
CYCLIC PRESSURE PRIME PLUG CQ
SWITCH VEHICLE HARNESS
CONNECTOR
BATT +----------' >2'r-t CD
A13591A
..
m
a=
c
I'll
MANIFOLD
ABSOLUTE
fn ~
PRESSURE (MAP)
-I
m ;:
.....
IGN START SW NEUTRAL
AIT DRIVE
LH HEATED
EXHAUST
RH HEATED
EXHAUST ENGINE THRonLE
SENSOR
-OR-. EGR VALVE MASS VEHICLE :.
SWITCH
STARTER
HEGO
GAS OXYGEN GAS OXYGEN
SENSOR SENSOR
COOLANT
TEMP SENSOR
POSITION AIR CHARGE
SENSOR TEMP SENSOR
BAROMETRIC POSITION
PRESSURE SENSOR
AIR FLOW
(MAF)
SPEED
SENSOR SELFTEST
z
c;) ft) I
GROUND (HEGOI (HEGO) (ECT) (TP) (ACT) SENSOR (BP) (EVP) SENSOR .(VSS) I'll
~
CONNECTOR
~
~ CL::~:
~
i ~ ~ 1 m1f I."" mn~

CO
.
,"~ J'
't ( I\WiELF'' '
ENGINE
:L SO
30 SWITCH CD
cc ~ en
II I ~ ~i.'i~ I! .....
~ NEUTRAL POWER . POWER 46 "5' 3 .. 00 C c
30~
50 MAF
9 MAFRTN I
GEAR
-16 SWITCH
49
GND
43
GND
29
7
146
26
1147
46
125
45
1126
46
1126 II
9
140/60
I LIGHT (I)
""CD
3 VSSDIF+ 3
6 VSSDIF
49 HEGO GND S- -I
CD
;:,
..
6O-PIN 43 H'EGO"L ft)
20 40 60
29 HEGOR
a
"
7 ECT
D,)
47E
25~
TO C
IGNITION
45 !!.E...
27 EVP
RUN
~
CD
;:,
26 VREF co
46 SIG RTN
17 STOiMiL
...CD
ill 0
48
4
1DM 22K OHMS
vvv , . . IGNITION RUN
CIRCUIT
...I
~'ii~~~
56 ~1:aUT I
,.--------~
, , \
~
36-- I I . :: '
16~A~~~~D
20~
\Ln_n __ ~ ~i; gPCONJ:6TOR
13 iNJ.3
12 iNJ.2
1 2 INJECTORS 3 4
59 iNJ.1 5 6 7 8
1 21 41
58 iNJ:S
14 iNJ.6
15 INj.7
42 iNJ-i
52A'M2
32AM'i
38C'ANp
31 EVA"
33FP"
22iSC 22 I
21~
~
37 VpWR T IDLE
- ......~-....j.----~~-- ....+---_...+ - - - - - - - - - - - - - - - - . - 3 7 / 5 7 -
57--
SPEED
CONTROL
BYPASS
AIR
(ISCBPA)
EGR
VACUUM
CANISTER
PURGE
AIR
MANAG,
AIR
MANAG 2
I
9 FPM REGULATOR SOLENOID (TAB) (TAD)
(EVR) (CANp) 37/57
1 KApWR
o PWR GND
o PWR GND
4 WAC
ACCS
(I)~c.n
ALL RIGHTS RESERVED
C
BAn 4 .~ ~
" 10
TO
m
."
... <=
AlC OEM CYCLIC IGNITION ....
..-_ _--J
r-
A127898
SWITCH PRESSURE SWITCH
SWITCH ....
en

G)
CD
1570 EEC-IV - Engine Supplement - Passenger Car
5.0L
SEFI
NON MASS AIR: CROWN VICTORIA, GRAND MARQUIS, MARK VII
Car Lines
Crown Victoria!
Mark VII Grand Marquis
Wire Wire
Pin Crt. # Color Crt. # Color Application Abbreviations
1 38 BK/O 37 Y Keep Alive Power KAPWR

2 511 LG 511 LG Brake On/Off BOO
3 150 DG/W 150 DG/W Vehicle Speed Sensor (+) VSS DIF (+)
4 11 DG/Y 11 DG/Y Ignition Diagnostic Monitor 10M
6 683 P/LB 359 BK/W Vehicle Speed Sensor (-) VSS DIF (-)
7 354 LG/Y 354 LG/Y Engine Coolant Temperature ECT
10 348 LG/P 883 PK/LB A/C Cycling Switch ACCS
11 99 LG/BK 99 LG/BK Air Management 2 AM2
12 557 BR/Y 557 BR/Y Injector #3 INJ 3
13 558 BR/LB 558 BR/LB Injector #4 INJ 4
14 559 T/LB 559 T/LB Injector #5 INJ 5
15 560 LG 560 LG Injector #6 INJ 6
16 259 BK/O 259 BK/O Ignition Ground IGN GND
17 382 Y/BK 201 T/R Self-Test OutpLltl"CHECK ENGINE" Light STO/MIL
20 57 BK 57 BK Case Ground CASE GND
21 264 W/LB 264 W/LB Idle Speed Control - Bypass Air ISC-BPA
22 97 T/LG 97 T/LG Fuel Pump FP
25 357 LG/P 357 LG/P Air Charge Temperature ACT
26 351 O/W 351 O/W Reference Voltage VREF
27 352 BR/LG 352 BR/LG EGR Valve Position Sensor EVP
29 94 DG/P 94 DG/P HEGO-R
Sensor - Right
30 33 W/PK 33 W/PK Neutral Drive Switch NOS
31 101 GY/Y 101 GY/Y Canister Purge CANP
33 360 DG 360 DG EGR Valve Regulator EVR
34 305 LB/PK 305 LB/PK Data Output Line DOL
35 146 W/PK 146 W/PK Speed Control Vent (Solenoid) SCVNT
36 '324 Y/LG 324 Y/LG Spark Output SPOUT
38 145 GY/BK 916 LG Speed Control Vacuum (Solenoid) SCVAC
(Continued) .

ALL RIGHTS RESERVED
5.0L
EEC-IV. Module Connector Pin Usage
SEFI
NON MASS AIR: CROWN VICTORIA, GRAND MARQUIS, MARK VII
Car Lines
Crown Victorial
Mark VII Grand Marquis
Wire Wire
Pin Crt. # Color Crt. # Color Application Abbreviations
39 199 LB/Y 679 GY/BK Speed Control Command Switch Ground SCCS GND
41 144 O/Y 144 O/Y Vehicle Speed Control Solenoid SOL (+)
42 561 T/O 561 T/O Injector #7 INJ 7
43 90 DB/LG 90 DB/LG HEGO-L
Sensor - Left
45 356 DB/LG 358 LG/BK Manifold Absolute Pressure Sensor MAP
46 359 BK/W 359 BK/W Signal Return SIG RTN
47 355 DG/LG' 355 DG/LG Throttle Position Sensor TP
48 209 W/R 200 W/BK Self-Test Input STI
49 89 0 89 0 Heated EGO Ground HEGO GND
50 151 LB/PK 151 .LB/BK . Speed Control Command Switch secs
51 100 W/R 100 W/R Air Management 1 AM1
52 562 LB 562 LB Injector #8 INJ 8
54 73 O/LB 73 O/LB Wide Open Throttle A/C Cut Off WAC
56 349 DB 349 DB Profile Ignition Pick-Up PIP
58 555 T 555 ~
T Injector #1 INJ 1
59 556 W 556 W Injector #2 INJ 2

-
60 '000000000051 @500000000000
- 1 41
damage to the pin connectors. Always probe as directed, 40 000000000031 0 300000000000 21
using the Breakout Box. 20 1\.. 0000000000" 100000000000 1

ALL RIGHTS RESERVED
5.0L
SEFI
MASS AIR: CROWN VICTORIA/GRAND MARQUIS

5 511 LG Brake ON/OFF BOO
6 359 BK/W Vehicle Speed Sensor (-) VSS (-)
8 695 BK/O Data (-) Data (-)
12 557 BR/Y Fuel Injector #3 INJ 3
13 558 BR/LB Fuel Injector #4 INJ 4
14 559 T/LB Fuel Injector # 5 INJ 5
15 560 LG Fuel Injector #6 INJ 6
17 201 T/R Self-Test Out and Malfunction Light STO and MIL
19 461 0 Fuel Pump Monitor FPM (-)
21 264 W/LB Idle Speed Control Bypass Air ISC-BPA
25 357 LG/P Air Charge Temp ACT
27 352 BR/LG EGR Valve Position Sensor EVP
29 94 DG/P HEGO-R
Sensor - Right
30 33 W/PK Neutral Drive NOS
32 99 LG/BK Thermactor Air Diverter (AM2) TAD
38 100 W/R Thermactor Air Bypass (AM 1) TAB
(Continued)

ALL RIGHTS RESERVED
5.0L
SEFI
MASS AIR: CROWN VICTORIA/GRAND MARQUIS

42 561 TIO Fuel Injector #7 INJ 7
43 90 DB/LG HEGO- L
Sensor - Left
44 696 O/BK Data (+) Data (+)
47 355 DG/LG Throttle Position Sensor TPS
49 89 0 HEGO GND
Ground
50 967 DB/O Mass Air Flow MAF
52 562 LIB Fuel Injector #8 INJ 8
54 73 O/LB W.O.T. AIC Cut Off WOT AIC
56 349 DB Profile Ignition Pick Up PIP
58 555 T Fuel Injector # 1 INJ 1
59 556 W Fuel Injector #2 INJ 2

-
60f000000000051 @OOOOOOOOOOO
- 41
damage to the pin connectors. Always probe as 40 000000000031 0 300000000000 121
directed, using the Breakout Box. 20..... 0 000000 000 10 0 00 00 000 0 0 I 1
11

ALL RIGHTS RESERVED
5.0L
EEC-IV Module Connector Pin Usage. MA
SEFI
MASS AIR: MUSTANG

6 563 O/Y Vehicle Speed Sensor (-) VSS (-)
12 557 BR/Y Fuel Injector #3 INJ 3
13 558 BR/LB Fuel Injector #4 INJ 4
14 559 T/LB Fuel Injector #5 INJ 5
17 657 T Self-Test Out and Malfunction Light STO and MIL
19 787 PK/BK Fuel Pump Monitor FPM (-)
21 264 W/LB Idle Speed Control Bypass Air ISC-BPA
29 94 DG/P HEGO-R
Sensor - Right
30 771 PlY Neutral Gear SW. M.T. NGS
30 771 PlY Neutral Drive With Automatics NOS
32 99 LG/BK Thermactor Air Diverter (AM2) TAD
38 100 W/R Thermactor Air Bypass (AM 1) TAB
(Continued)

ALL RIGHTS RESERVED
5.0L
SEFI
MASS AIR: MUSTANG

43 90 OB/LG HEGO-L
Sensor - Left
47 355 OG/LG Throttle Position Sensor TPS
48 201 T/R Self-Test Input STI
49 89 0 HEGO GNO
Ground
50 967 OB/O Mass Air Flow MAF
52 562 LB Fuel Injector # 8 INJ 8

connector with OVOM probe will result in permanent
damage to the pin connectors. Always probe as
-
60 '00000000005'
40 - 000000000031 0
...
(~:roooooooooo
300000000000
41
21
directed. using the Breakout Box. . 20 1 0000000000" 100000000000 1

ALL RIGHTS RESERVED
5.0L
/NON MA
. SEFI
TOWN CAR

1 554 Y/BK Keep Alive Power KAPWR
3 136 Y/LB Vehicle Speed Sensor (+) VSS (+)
4 20 W/LB Ignition Diagnostic Monitor IDM
5 475 DG/W Brake ON/OFF BOO
6 875 BK/LB Vehicle Speed Sensor (-) VSS (-)
8 915 PK/LB Data (-) Data (-)
9 968 T/LB Mass Air Signal Return (California only) MAF ATN
10 585 PK A/C Clutch Signal ACCS
12 557 BA/Y Fuel Injector # 3 INJ 3
13 558 BA/LB Fuel Injector #4 INJ 4
14 559 T/LB Fuel Injector #5 INJ 5
17 201 T/R Self-Test Out and Malfunction Light STO and MIL
19 787 PK/BK Fuel Pump Monitor FPM (-)
21 265 LG/W Idle Speed Control Bypass Air ISC-BPA
22 926 LB/O Fuel Pump FP
26 351 .0/W Reference Voltage VAEF
27 352 BA/LG EGR Valve Position Sensor EVP
29 94 DG/P HEGO-R
Sensor - Aight
30 33 W/PK Neutral Drive With Automatics NDS
32 274 0 Thermactor Air Diverter (AM2) TAD
34 205 DB/LG Data Output Link DOL
36 395 GY/O Spark Out SPOUT
38 275 Y Thermactor Air Bypass (AM 1) TAB
(Continued)

ALL RIGHTS RESERVED
5.0L
/NON MA
SEFI
TOWN CAR

43 74 DG/Y HEGO-L
Sensor - Left
44 223 T/LG Data (+) Data (+)
47 355 DG/LG Throttle Position Sensor TPS
49 394 GY/LB HEGO GND
Ground
50 967 DB/O Mass Air Flow (California only) MAF
52 562 LB Fuel Injector' # 8 INJ 8

connector with DVOM probe will result in permanent ooro - -
00000000 051 @OOOOOOOOO 00 41
damage to the pin connectors. Always probe as 40 . 00 00000 00031 0 300 000 0 000 00 21
directed, using the Breakout Box. 20 0 000000 000 10 000 00 000 00 1
\...
11

ALL RIGHTS RESERVED
~5-78 EEC-IV - Engine Supplement - Passenger Car
Quick Test Codes and Code Definitions 5.0L
ALL 5.0L PASSENGER CAR
...
11 orc System PASS
13'
14 c
15 0
r
....
Cannot control rpm during Self-Test low rpm check
PIP circuit failure
ECA Read Only Memory (ROM) test failed
15 c
16 r ..
Rpm too low to perform EGO test
......
18 c IDM circuit failure/SPOUT circuit grounded
19 0 Failure in ECA internal voltage
21 or ECT out of Self-Test range
22 oc
23 or ..
MAP/BP out of Self-Test range
TP out of Self-Test range
24 or
26 or ...
ACT out of Self-Test range
MAF out of Self-Test range (MA only)
29 c
31 orc ..
Insufficient input from the Vehicle Speed Sensor (VSS)
EVP circuit below minimum vOlta~e
32 orc
33 rc ..
EVP voltage below closed limit ( ONIC)
EGR valve opening not detected (SONIC)
....
34 orc EVP voltage above closed limit (SONIC)
35 orc EVP circuit above maximum voltage
41 r HEGO sensor circuit indicates system Jean (right HEGO)
41 c No HEGO switch detected (right HEGO)
42 r
44 r ..
HEGO sensor circuit indicates system rich (right HEGO)
Thermactor air system inoperative (right side)
.....
45 r Thermactor air upstream during Self-Test
46 r Thermactor air not bypassed during Self-Test
51 oc ECT indicated - 40F/circuit open
53 oc TP circuit above maximum voltage
54 oc
56 oc ..
ACT indicated - 40F/circuit open
MAF circuit above maximum voltage (MA only)
61 oc
63 oc ..
ECT indicated 254F/circuit grounded
TP circuit below minimum voltage
64 oc
66 c ..
ACT indicated 254F/circuit grounded
MAF circuit below minimum voltage (MA only)
67 0
74 r
75 r
...
Neutral Drive Switch (NDS) circuit open
Brake ON/OFF (BOO) circuit open/not actuated during Self-Test
Brake ON/OFF (BOO) circuit closed/ECA input open
77 r
79 0 ..
Brief WOT not sensed during Self-Test/Operator error
A/C on/Defrost on during Self-Test
81 0
82 0 ..Air Management 2 (AM2) circuit failure
Air Management 1 (AM1) circuit failure
84 0
85 0 ..
EGR Vacuum Regulator (EVR) circuit failure
Canister Purge (CANP) circuit failure
87 oc
91 r ..
Fuel pump primary circuit failure
HEGO sensor circuit indicates system lean (left HEGO)
91 c
92 r ..
No HEGO switching detected (left HEGO)
HEGO sensor circuit indicates system rich (left HEGO)
94 r
95 oc
96 oc
...
Thermactor air system inoperative (left side)
Fuel pump secondary circuit failure
Fuel pump secondary circuit failure
..
98 r Hard fault is present - FMEM mode
NO CODES Unable to initiate Self-Test or unable to output Self-Test codes
CODES NOT LISTED Service codes displayed are not applicable to the vehicle being tested

ALL RIGHTS RESERVED
SECfION 16
EEC-IV-Engine Supplement -
Light Truck
Contents
Diagnostic SensorI Actuator Referen~e Values - Truck 16-1
2.3L EFI
Quick Test Code and Code Definitions 16-6
2.9L EFI
2.9L MA EFI
Electrical Schematic............................................................... 16-1 0
3.0L EFI
4.0L MA EFI
(Continued)

ALL RIGHTS RESERVED
SECTION 16
EEC-IV-Engine Supplement -
Light Truck
Contents
4.9L EFI
5.0L EFI
5.8L EFI
7.3L E40D Diesel
7.5L EFI

ALL RIGHTS RESERVED
EECIV - Engine Supplement - Light Truck 161
Diagnostic Sensor/Actuator Reference Values Truck
NOTE:
The chart below contains typical component values.
Values measured in the field may differ slightly from those shown.
Do not compare reference values found on this chart with monitor-box data. Monitor-box data is measured with
respect to a different reference level in some cases.
Breakout box pin number assignments differ from vehicle to vehicle. Refer to Jhe Pin Usage Chart applicable
to the vehicle being serviced for the correct pin assignments.
Each vehicle application will not have all components listed below.
Pre-condition the engine in the following. manner before recording any values:
- The engine should be. at a normal operating condition.
- Start and run engine at 2000 rpm for two minutes.
Breakout KEY OFF

Box Pin Throttle Key On Hot
Numbers Closed Eng. Off Idle
INPUTS (+) (-) (ohms) (volts) (volts)
* Clutch Engage Switch (CES) CD 30 40 - - -
Coil Tach Signal (10M) 4 16 21.8 K 8.0 to 10.0 8.0 to 12.0
* Distributor Position (PIP) ,56 16 1.1 K to 2.1 K - 3.0 to 7.0
EGR Valve Position (EVP) 27 46 480 K to 650K 0.30 to 0.45 0.30 to 0.45
* Engine Coolant Temperature (ECT) 7 46 1.7 K to 3.6 K - 0.31 to 1.0
(Heated) Exhaust Gas Oxygen (H) EGO 29 46 > 1.5 M < 0.4 0.0 to 0.9
* Knock Sensor (KS) 0 23 46 4.5 K to 6.5 K - -
Manifold Pressure (MAP)
*
Barometric Pressure (BP) 45 46 - - -
* Mass Air Flow (MAF) 50 40/60 - - -
* Neutral/Drive Switch (NOS) 0 30 40 - - -
* Power Steering Pressure Switch (PSPS) 24 46 - - -
Pressure Feedback EGR (PFE) 27 46 - 3.0 to 3.5 3.0 to 3.5
Reference Voltage (VREF) 26 46 - 5.0 5% 5.0 5%
Throttle Position (TP) 47 46 0.5 K to 1.2 K 0.7 to 1.3 0.7 to 1.3
* Vehicle Speed Sensor (VSS) 3 6 190.0 to 240.0 - -

OUTPUTS
* Canister Purge (CANP) @ 37 31 60.0 to 70.0 0.0 0.0
Computed Spark Advance (DIS) 36 16 - 9.0 to 12.5 8.5 to 9.5
Computed Spark Advance (TFI) 36 16 - 0.0 5.0 to 7.0
EGR Valve Regulator (EVR) 37 33 40.0 to '50.0 0.0 (OFF) 0.0 (OFF)
Fuel Pump Relay (FP) 37 22 - 0.0 (OFF) VBAT (ON)
* Idle Speed Bypass (IBA) Q:Y 37 21 9.5 to 11.5 0.0 (OFF) 2.0 to 5.5
* Injectors Bank # 1 @ 37 58 - 0.0 -
* Injectors Bank #2 @ 37 59 - 0.0 -
Spark Angle Word (SAW) 36 16 - - 0.5 to 0.7
* Numbers to the right of these Inputs/outputs refer to explanations on next page.

ALL RIGHTS RESERVED
16-2 EEC-IV - Engine Supplement - Light Truck
Diagnostic Sensor/Actuator Reference Values Truck
Explanations -
CD If the clutch is pedal down, the switch is closed. If the clutch is pedal up, the switch is
open.
For applications containing TFI-IV systems only.
Engine coolant temperature must be within the 180-240F (82-116C) temperature range
before measurements are taken.
o The Knock Sensor output voltage is a variable signal of 300 mV or greater, depending on
the severity of engine knock; background noise is not part of the sensor output.
@) Refer to the Altitude vs. Voltage Chart in Pinpoint Test OF, Section 17 for proper
operating values.
Refer to the MAF Sensor data chart in Pinpoint Test OC for proper operating values.
CD The NOS is open in any gear, but closed in neutral or park.
If power steering pressure rises above a specified limit, the switch contacts will open and
the ECA will adjust idle speed to compensate for the extra load placed on the engine.
If vehicle is not moving, the speed sensor output to the processor will be zero. The
vehicle must be moving for the speed sensor to provide information to the processor.
@ Not all applications will use pin 31 for canister purge. Refer to appropriate vehicle pin
usage chart.
QJ) Idle Speed Bypass resistance is typically 9.5 to 11.5 ohms, except on 5.0L F-Series, the
resistance range is 17 to 21 ohms.
@ Refer to the Injector Resistance Chart in Pinpoint Test H, Section 17 for the proper
resistance values.

ALL RIGHTS RESERVED
m
m
nI
;-49STATEsl
I ONLY I j--CALiF. -1
~'ILY I rn
.... <:
I,
HEATED ENGINE
MfT
11 CLUTCH
ENGAGE
EXHAUST COOLANT THROTTLE
HEGO GAS OXYGEN TEMPERATURE POSITION AIR CHARGE
S5 I
~
I
a
..... ) --< LOW I
m
lTo~f(--::'
30 SWITCH SENSOR (HEGO) (ECT) (TP) TEMP (ACT) F) I
~ ~~::' ~g;'i~GA~~NDS'fJE~ ~SENSOR BT~~EI~P~~ST :~o

~
OR :
co
A
~ ~I
S,ENSOR S!ENSOA
~~16 Iilo [}
I
I ....
n
S
CD
I
I
L
AfT
18'
OCT
ADJ
lhf{0
~-
STARTER
RELAY NEUTRAL
GEAR
SWITCH:
~.:
7Z:.
C
:
49 29 7
46
26
47
46
25
46
45
3
6
r:L
27
46
46
24
2
-=
,.....-
17
(STI)
.
tf
48 . 22 15
I
....
AJ en
c
"a
"a
CD
~fo"g~o' ~
POWER 46 36 26 TO IGN 14
~ (J)
CE,] " . - GNO tRUN
n 3
-
~
29
7 ::ra CD
~
.....
U TP
~ I
a
ACT
~
MAP
~
~
3 VSS DIF ( + ) ~~~~~:.. C
-.
_
60-PIN
V EVP MfT LIGHT AJ ~
M PSPS
2 BOO
20 40 60
U VREF
~
SIG RTN
n ~
c
9
DATA(-) n
W
17
DATA (+)
!';TO/SIL
STI
'"
~
m MAF RTN
MAF
M
4 10M - TO IGNITION RUN
~ PIP '~-------- ....'
I, 1\ LS6 ~1 0 I
. 4 j]'2 CIRCUIT ONLY INJECTORS
~
~
~
~
~
SPOUT
16 IGNGND
~:~'
INJ BANK'
GN'
i
'..1

I
--------1'
:
\
I~
I
7 it" 36
0
04
~
l g~NNECTOAS r"
g
09
O!
16
58
+
~~_~~
1 2
Jff'.JfF~
1
3
I
4
INJ BANK 2 59
~
~-------------37/57""-----<"'---_-----'
1 21 41 53 CCO AfT 53
33
52
E~~fT 33- 40/60.
S 52 37/57 I 37/57 3 7/57
21 ISCBPA
37 VPWR
57 VPWR J GI1
~I
IDLE
SPEED
~
[~A~\
~
~ CONVERTER
CLUTCH
OVERRIDE AND
TO
FUEL
PUMP
I
8 22
2J CONTROL EGR SHIFT SOLENOIDS. ;- ~
BYPASS VACUUM (CCO. SS) .,
AIR REGULATOR (AfT ONLY) -'
KAPWR (ISCBPA) (EVR) ~ 1 ,~ "L.::.
40
PWR GND
60 PWR GND
on EEC ~ FUE
_ POWER R
6 VSS OIF (.) _ CYCLIC RELAY
10 ACCS -~ P~~~i~~E L-_B_AT_T_E_R_Y
r
--o
~~~ ~
54
43 43
- TO
"- IGNITION
BATT + . . . - ~ """'- ~~~~~~RUN
AlC OEM ~':: T -b
1~ CIRCUIT
rn~
8
FPM SWITCH WAC -=-
ALL RIGHTS RESERVED
I
RELAY AIC
N >TE: WIRING SCHEMATIC SHOWS PIN OUT LOOKING INTO HARNESS CONNECTOR
..,,~
A8948E
.... r- -"
en
I
w
Distributorless Ignition System (DIS) 2.3L

Electrical Schematic EFI
OPI
VSA"r. KEY POWER

80TH START AND RUN DUAL HALL ,----------------------
I
--
SENSOR !
(PIP/CIO) I
I
o
DIS
MODULE
(FRONT VIEW)
SECONDARY DIS PRIMARY DIS

COILS COILS
LEFT SIDE RIGHT
SPOUT OF ENGINE SIDE OF
I ENGINE
I DISCONNECT
I LOCATED
I
I ADJACENT TO 10M
I 1-6 PINS
I MODULE CONNECTOR
I
I
L oJ ~
,-= --------;..1 VBAl

-TEST PINS LOCATED ON BREAKOUT BOX.
ALL HARNESS CONNECTORS VIEWED INTO IlAnNG SURFACE.
A12785-B

ALL RIGHTS RESERVED
EEC-IV - Engine Supplement - Light Truck 16-5
2.3L
EFI
2 511 LG Brake OnlOff BOO
3 150 DG/W Vehicle Speed Sensor (+) VSS DIF(+)
4 11 \ DG/Y Ignition Diagnostic Monitor IDM
6 563 O/Y Vehicle Speed Sensor (-) VSS DIF( -)
8 238 O/LB Fuel Pump Monitor FPM
9 96 T/O Data (-) Data (-)
10 198 T/Y A/C Cycle Pressure Switch ACCS
14 967 DB/O Mass Air Flow Signal (California Only) MAF
15 968 T/LB Mass Air Flow Signal Return (California Only) MAF RTN
17 201 T/R Self-Test Output STO
18 240 W/R Octane Adjust Switch OCT ADJ
20 57 . BK Case Ground CASE GND
21 67 GY/W Idle Speed Control (Bypass Air) ISC-BPA
25 310 Y/R Air Charge Temperature ACT
27 352 BR/LG EGR Valve Position (MIT Only) EVP
28 95 T/R Data (+) Data (+)
30 200 W/BK Neutral Drive Switch (A/T Only) NDS
30 200 W/BK Neutral Gear Switch and Clutch Engage Switch (MIT Only) NGS/CES
32 395 GY/O Dual Plug Inhibit DPI
33 360 DG Exhaust Gas Recirculation Valve Regulator (MIT Only) EVR
45 .356 DB/LG Manifold Absolute Pressure (49 States Only) MAP
52 224 T/LB Shift Solenoid (A/T Only) SS
53 332 W Clutch Converter Override (A/T Only) CCO
54 462 P W.O.T. A/C Cut Off WAC
Vehicle Power .. VPWR
57 361 R
58 555 T Injector (Bank 1) INJ Bank 1
59 556 W Injector (Bank 2) INJ Bank 2
Pin locations given for reference only. ~robing 60 pin connector with
DVOM probe will result in permanent damage to the pin connectors. 'OfO
40
-
0000000005'
000000000031
@OOO
0
- 0 00 00 000
300000000000 121
141
Always probe as directed, using the Breakout Box. 20 \.. 0 000000 000, , 10 0 00 00 000 00 1 1

ALL RIGHTS RESERVED
166 EECIV - Engine Supplement - Light Truck
2.3L
EFI
18 c ~ Erratic IDM input to processor
21 or ~ Engine Coolant Temp (ECT) out of Self-Test range
22 orc ~ Manifold Absolute Pressure (MAP) out of Self-Test range
23 or ~ Throttle Position (TP) out of Self-Test range
24 or ~ Air Charge Temp (ACT) out of Self-Test range
28 c ~ Loss of IDM - right side
32 orc ~ EVP voltage below closed limit
35 orc ~ EVP circuit above maximum voltage .
48 c ~ Loss of IDM - left side
52 0 ~ Power Steering Pressure Switch (PSPS) circuit open
67 0 ~ Neutral Drive Switch (NDS) circuit open/A/C on
74 r ~ Brake On/Off (BOO) circuit failure/not actuated during Self-Test
77 r ~ Operator error (Dynamic Response/Cylinder Balance Tests)
86 0 ~ Shift Solenoid (SS) circuit failure
87 oc ~ Primary Fuel Pump circuit failure
88 c ~ Loss of Dual Plug Input control
89 0 ~ Clutch Converter Override (CCO) circuit failure
95 oc ~ Fuel Pump circuit open - ECA to motor ground
96 oc ~ Fuel Pump circuit open - battery to ECA
KEY: 0 = Key On Engine Off (KOEO) r = Engine Running c = Continuous Memory

ALL RIGHTS RESERVED
;U m
~ m
0
Rl Z
1 <
Q
MfT CLUTCH HEATED ENGINE AIR MANIFOLD BRAKE m
~ ENG. SWITCH EXHAUST
GAS OXYGEN
COOLANT THROTILE
TEMP. POSITION
CHARGE
TEMP.
ABSOLUTE PRESSURE VEHICLE ONIOFF
PRESSURE KNOCK FEEDBACK SPEED SWITCH
;U
.......
I
IGN. SrRT SW NEUTRAL HEGO SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR EGR SENSOR (BOO) SELFTEST
OJ
m
:J
~ ~~'~~H ~~ GR;ND t@(HEGO) ~c;~ r1J}(TP) ~(A~CT) (~A~) (; ~(PFE) (VSS) BA; t C~ONN~UCI\TO_R .., ;U CO
S'
AA
. STARTER
D ~ ~ ~~ ~~~~ 'l:
~p,~~ ~ ~ ~1, BRAKE
SWITCH 0 ol~SELF'T~ST
n. INPUT
0
Z CD
RELAY NEUTRAL U (STI) 0 'CJ)
s~~f~ B~~K: 0 0 C
- ""CD
30
NDS/NGS & CEsl
HEGOG
POWER
GND -
~ 3
-....I
4 CD CD
HEGO
29 :J
ECT
tn
4
TP
-t
2
ACT
~
MAP
4 -f ~.
m
- -...
6O-PIN KS
23
2
PFE tn :so
20 40 60 VREF
26
BOO -t
VSS DIF It) c
6
VSS OIF 1-) n
~
4 SIG RTN
1 STO
4 STI
10M 22K PIiMS
PIP ;~_v_v .... , ~ ~~~
5
36 SPOUT : '. f " CIRCUIT
1
20 ~A~c;~~~D
FP
\ -~-------~. -:::-
, LjIW
~CONNECTOR
TF' ~~~
2
5 INJ BANK 1
INJ BANK 2
I ~ I~:. I~:I
5
5 CCO 1 INJECTORS 2 3
;!R ~~~6
33
2
I
1 21 41 3
5
VPWR T ~
.. ~Cg~~~~L
IDLE 4n EGR
~~
CONVERTER
~~
I'-- '--~
BYPASS VACUUM CLUTCH
AIR REGULATOR OVERRIDE
(ISC-BPA) (EVR) SOLENOID TO ~
(Jcg~l Y) ~~~~ - rrfO b I JI

40
60 ::W~~~ ~ '::'
EEC
POWER
,~~ FUELP~MP RELAY
10 ACC BATTERY RELAY

54
WAC
BATT. _ _
AlC OEM.
r--lL
- ~
~ ~
-
-:i:-
IGNi~ON
s.;::g/~~N
rn~
SWITCH rvrllr CIRCUITS
RELAY PRESSURE AlC
.,,\c
ALL RIGHTS RESERVED
SWITCH CLUTCH A9126-B
..... r-
.....
G)

.....
2.9L
EFI
RANGER/BRONCO II (49 STATES)

1 554 YfBK Keep Alive Power KAPWR
2 511 LG Brake On-Off (AfT Only) BOO
7 354 LG/Y Engine Coolant Temp. Sensor ECT
17 201 T/R Self-Test Output and "CHECK ENGINE" Light STO and MIL
25 357 LG/P Air Charge Temp. Sensor ACT
30 200 W/BKo Neutral Drive Switch (A/T Only) NDS
30 200 W/BK Clutch Interlock Switch (MIT Only) CIS
37 3~1 R Vehicle Power VPWR
54 462 P W.O.T. A/C Cut-Off WAC
58 555 T Bank 1 Injector (Controls Engine Cylinder Numbers 1, 2 and 4) INJ BANK 1
59 556 W Bank 2 Injector (Controls Engine Cylinder Numbers 3, 5 and 6) INJ BANK 2
Pin locations given for reference only. Probing 60 pin connector with - -
6~1
000000000051 @OOOOOOOOOOO 41
Always probe as directed, using the Breakout Box.
40 000000000031 0
300000000000 21
20 0000000000 11 100000000000 1

ALL RIGHTS RESERVED
2.9L
Quick Test Codes and Code Definition
EFI
RANGER/BRONCO II (49 STATES)
....
11 orc System PASS
......
13 r Cannot control rpm during Self-Test low rpm check
14 c PIP circuit failure
15 0 ECA Read Only Memory (ROM) test failed
.....
15 c ECA Keep Alive Memory (KAM) test failed
18 c Loss of IDM input to Processor/SPOUT circuit grounded
.....
19 0 Failure in ECA internal voltage
21 or Engine Coolant Temp (ECT) out of Self-Test range
22 orc Manifold Absolute Pressure (MAP) out of Self-Test range
......
23 or Throttle Position (TP) out of Self-Test range
24 or Air Charge Temp (ACn out of Self-Test range
29 c Insufficient input from the Vehicle Speed Sensor (VSS)
....
41 r HEGO sensor circuit indicates system lean
41 c No HEGO switch detected
42
51
r
oc .... HEGO sensor circuit indicates system rich
ECT indicated - 40F/circuit open
......
53 oc TP circuit above maximum voltage
54 oc ACT indicated - 40F/ circuit open
61 oc ECT .indicated 250F/circuit grounded
....
63 oc TP circuit below minimum voltage
64 oc ACT indicated 254F/circuit grounded
67 0 Neutral Drive Switch (NDS) circuit open/A/C on
.....
67 c Clutch Switch circuit failure
72 r Insufficient MAP change during Dynamic Response Test
73 r Insufficient TP change during Dynamic Response Test
74
77
r
r ... Brake On/Off (BOO) .circuit failure/not actuated during Self-Test
Operator error (Dynamic Response/Cylinder Balance Tests)
...
86 0 Shift Solenoid (SS) circuit failure
87 oc Primary Fuel Pump circuit failure
89
95
0
oc .. Clutch Converter Override (CCO) circuit failure
Fuel Pump circuit open - ECA to motor ground
......
96 oc Fuel Pump circuit open - battery to ECA
98 r Hard fault present
NO CODES Unable to initiate Self-Test or unable to output Self-Test codes
CODES NOT LISTED Service codes displayed are not applicable to the vehicle being tested

ALL RIGHTS RESERVED
I~
CLUTCH - INTERLOCK
:D
~
z
...
MfT CLUTCH SWITCH
ENG SWITCH 46 i
Q
I :l 30
...-.:
HEATED ENGINE BRAKE
m 'lTJ
:D .)
t
TO MASS EXHAUST COOLANT THROTTLE AIR VEHICLE ON/OFF
TO IGN. BATTERY AIR FLOW GAS OXYGEN TEMP POSITION CHARGE SPEED (BOO)
'" n
....
''
OJ
~~M
I '*~~-+ ..... TO STARTER
~~
SENSOR
(HEGO)
SENSOR
(ECT)
SENSOR
(TP)
SENSOR
TEMP (ACT)
SENSOR
SENSOR
(VSS)
SWITCH
BATT +
SELF-TEST
CONNECTOR :D
0 .......
r@ $~j
MOTOR
~
f ~.
...n
TO IGN. START S:EUTRAL -:- -:- Z
0
-i DRIVE Sw.
yrID:q: TO
,
/ ::. BRAKE
SWITCH 0
SELFTEST
INPUT
0
0 C
I,l '~I 11
(STI)
--
30-0 BATTERY BRAKE 0 r.;'I,
AfT 00 TO STARTER 14 I 140/60 TO 29 7 I 26 3 I
6 LAMP 't'"
(I)
I
MOTOR 46 26 47 46 . 2 -::- 46 17 48 22
NOS CIS I -:- STARTER ~ 15 ~
PWR
GND 45 0 n
30
14
MAF
MAF RTN
. RELAY
37/57
~
c." :r
15 ~
aC
"CHECK
HEGOGND
49 ENGINE"
~ 0
HEGO LIGHT
29
:D
........
ECT 46/49 ~
7
z
-
TP
47
);
er"
SO-PIN ACT
25
20 40 60
26
VREF
n
BOO AfT TO
2 IGNITION
VSS DIF (+)
3 SWITCH
VSS DIF(-)
6
46 SIG RTN
STO & MIL
17
STI
48
10M 22~. ?,HM$ __ TO
4 PIP ,..:_v_v -,., COIL , ~ TO IGNITION
56 r-58~
36 SPOUT " \ " \ RUN CIRCUIT
.-59--+--r I
16
20
22
~~~~~~D
FP \_,L - -'\t" TFI
CONNECTOR II B~~ ",
",
INJ BANK 1
58
INJ BANK 2 o
59
h - .
53
52
CCO AfT
SS AfT ,
1
INJECTORS
2
5
4
6 <
1 21 41
21
37
57
ISC-BPA
VPWR
VPWR T
21
(i] " IDLE
53 52
37/57------+.+--------~~-----------'--""1
CONVERTER ~
I
",
co
,..J SPEED CLUTCH OVERRIDE L---l~f---""-+--"'"
CONTROL AND SHIFT S'
BYPASS SOLENOIDS CD
AIR
(ISC-BPA)
(CCO, SS)
(AfT ONLY)
rrh TO
FUEL PUMP ..
r
37/57
8
22 en
c
"'0
"'0
T CD
~ 3
-I
FUEL PUMP
RELAY
CD
~
ALL RIGHTS RESERVED
r-
m~~ cO'
..-
TO
CYCLIC
'~~I,~~~ 4 ' -n r-
.. \C :T
PRESSURE
SWITCH.
START/RUN
CIRCUiTS
....
AlC c
CLUTCH A13582-A n
NOTE: WIRING SCHEMATIC SHOWS PIN OUT LOOKING INTO HARNESS CONNECTORS ~
2.9L
EFI
RANGER/BRONCO II (CALIFORNIA)
2 511 LG Brake On-Off (A/T Only) BOO
3 150 OG/W Vehicle Speed Sensor (+) VSS DIF (+)
7 354 LG/Y Engine Coolant Temp. Sensor ECT
9 96 T/O Data Communication Link (-) Data (-)
14 967 OB/O Mass Air Flow Sensor MAF
21 67 GY/W Idle Speed Control (Bypass Air) ISCBPA
25 357 LG/P Air Charge Temp. Sensor ACT
28 95 T/R Data Communication Link (+) Data (+)
37 361 .R Vehicle Power VPWR
40 60 BK/LG Power Ground PWR GNO
54 462 P W.O.T. A/C Cut-Off WAC
Injector (Bank 1 - Controls Engine Cylinder Numbers 1, 2 INJ BANK 1
58 555 T and 4)
Injector (Bank 2 - Controls Engine Cylinder Numbers 3, 5 INJ BANK 2
59 556 W and 6)
Pin locations given for reference only. Probing 60 pin connector - -

with OVOM probe will result in permanent damage to the pin
connectors. Always probe as directed, using the Breakout Box.
.or00000000005' @OOOOOOOOOOO
40 000000000031
20 .... 0000000000
11
0
300000000000
100000000000
r'I 21
1

ALL RIGHTS RESERVED
2.9L
EFI
RANGER/BRONCO II (CALIFORNIA)

18 c ~ Loss of 10M input to Processor/SPOUT circuit grounded
21 or ~ Engine Coolant Temperature (ECT) out of Self-Test. range
24 or ~ Air Charge Temperature (ACT) out of Self-Test range
26 or ~ Mass Air Flow (MAF) out of Self-Test range
29 c. ~ Insufficient input from the Vehicle Speed Sensor (VSS)
56 oc ~ MAF circuit above maximum voltage
66 c ~ MAF circuit below minimum voltage
67 0 ~ Neutral Drive Switch (NOS) circuit open/A/C on
67 c ~ Clutch Switch circuit failure
86 0 ~ Shift Solenoid circuit failure
95 oc ~ Fuel Pump circuit open - ECA to motor ground

ALL RIGHTS RESERVED
m
m
CLUTCH-INTERLOCK TO TO IGN. START Sw. HEATED ENGINE AIR MANIFOLD POWER BRAKE o
....rn
SWITCH BATTERY
CLUTCH I
EXHAUST
GAS OXYGEN
COOLANT THROTTI.E CHARGE
TEMP POSITION TEMP
ABSOLUTE
PRESSURE
STEERING VEHICLE
PRESSURE SPEED
ON/OFF
(BOO) <:
_t (ECT) (TP) (ACT) (MAP) SWITCH SENSOR SELF-TEST
ENG. SWITCH
I
HEGO
GROUND
(HEGO)
SENSOR SENSOR SENSOR SENSOR SENSOR (PSPS) (VSS)
SWITCH
BATT + CONNECTOR
ft) I
m
a
~~ ~ ~
~
'I;"~-"\,
~
TOIGN.
START SW
~~~ BRAKE
SWITCH
SELF-TEST
INPUT
(STI)
....... co
s-eD
BRAKE
n
MIT
. 26 I 125
46
4-5 24
. LIGHT
46
i
48 22
....
I en
c
"a
"a
2"6 (I) CD
n 3
-= ::r' ~
-I
CD
..
ft)
a I
~
I
-.
60-PIN TO
20 40 60
IGNITION
SWITCH ....
n
:r
-f
c
n
~
IGN.
I .TO
COIL
RUN
CIRCUIT 58~ r ,I
, 37/57
1 21 41
CANISTER CONVERTER
PURGE CLUTCH
SOLENOID OVERRIDE
(CANP) AND SHIFT
SOLENOID
(CCO. SS) TO FUEL PUMP ill I. i
FPM (AIT ONLY)
3~ DOL ., TO INSTRUMENT I I I I
1 KAPWR PANEL
40~ 40
60~
5~
10~ 37/57
54~
... ,10
TO BATTERY ~ '- ~ ~~I~~~TlON
AlC OEM CYCLIC PR
.... '
(11~
ALL RIGHTS RESERVED
SWITCH SWITCH START/RUN

."c
AlC CLUTCH
CIRCUIT
A9127-E .... r- ....

m
....w
3.0L
EFI

2 810 R/LG Brake ON-OFF BOO
6 398 BK/Y Vehicle Speed Sensor (-) VSS DIF (-)
10 347 BK/Y A/C Cycle Pressure Switch ACCS
30 199 LB/Y Clutch Interlock Switch (MIT Only) CIS
30 199 LB/Y Neutral Drive Switch (A/T Only) NOS
53 332 W Converter Clutch Override (A/T Only) CCO
54 321 GY/W W.O.T. A/C Cut-Off WAC
58 96 T/O Injector (Bank 1 - Controls Engine Cylinder Numbers 1, 2

and 3) INJ BANK 1
59 95 T/R Injector (Bank 2 - Controls Engine Cylinder Numbers 4, 5

and 6) INJ BANK 2
60 60 BL/LG Power Ground PWR GND
Pin locations given for reference only. Probing 60 pin connector

with DVOM probe will result in permanent damage to the pin
-
6Ofooooooooo05'
-
500000000000 41
21
connectors. Always probe as directed, using the Breakout Box.
40 0000000000J1@JOOOOOOOOOOO
20," 000.0000000" '00000000000 ,

ALL RIGHTS RESERVED
EECIV - Engine Supplement - Light Truck '1615
3.0L
EFi

13 r ~ Cannot control rpm during Self-Test low rpm. check
18 r ~ .SPOUT circuit open
18 c ~ Loss of IDM input to Processor/SPOUT circuit grounded
21 or ~ Engine Coolant Temperature (ECT) out of Self-Test range
: 23 or ~ Thr~ttle Position (TP) out of' Self-Test range

..
51 oc ~ ECT indicated - 40F I circuit open
52 0 ~ Power Steering Pressure Switch (PSPS) circuit ope~
53 oc ~ TP circuit above maximum' voltage
6~ oc ~ . TP circuit below minimum voltage
67 0 ~ Neutral Drive Switch (NOS) circuit openl A/C on
72 r .~ Insufficient MAP change (juring- Dynamic Response Test
73 r ~ Insufficient TP change during Dynamic-Response Test -
74 r ~ Brake On/Off (BOO) circuit failure/not actuated during Self-Test.
77 r ~ Operator Error (Dynamic Response/Cylinder -Balance Tests)
89 0 ~ Clut~hConverter Override (C~O) circuit failure
95 oc ~ Fuel Pump circuit open. - ECA to motor ground

ALL RIGHTS RESERVED
...
en
...

en
MIT
CLUTCH - INTERLOCK
SWITCH
,---------46 , ....rn
R)
TO IGN.
START Sw.
BATTERY
TO MASS
AIR FLOW
(MAF)
HEATED
EXHAUST
GAS OXYGEN
(HEGO)
ENGINE
COOLANT THROTTLE
TEMP
(ECT)
POSITION
(TP)
AIR
CHARGE
TEMP (ACT)
OCTANE
ADJUST
PRESSURE
(BP)
SPEED
(VSS)
BRAKE
BAROMETRIC VEHICLE ON/OFF
(BOO)
SWITCH SElFTEST
a
.......
Stjt(~ W
SENSOR SENSOR SENSOR SENSOR BATT + CONNECTOR
rr~
TO IGN. START Sw. TO STARTER
t"
~
NEUTRAL
DRIVE SW.
3 0~O: ~
~
STARTER
RELAY
-=- MOTOR
r@ ~r-
: , ~t OO BRAKE
SWITCH
~D
0
SElF.TEST
INPUT
....C
, AfT
-0 BATTERY
TO
TO STARTER 1 I 46
I
26
BRAKE 0
(STI)
lp
(IJ
30 NOS CIS
45 BP
I ~ STARTER
RELAY
..... MOTOR POWER 29
GND
71 462647461 44 I
45
3
6
I ?.".
LAMP
46 17 48 22
g.
I R)
a
14..M&....- L.-..t40/60-
15~
49 1iEQ9...Q!'iQ
L......+37/57
I "CHECK
UI a....
ENGINE"
29~ LIGHT
7
ECT 46/49
47 TP
f"
6O-PIN 25 B
44~ t"
20 40 60 VREF
26
TO
2
3
e~~(+) IGNlTfON
SWITCH
6 VSS DIF (-)
SIG RTN
~ :"
4 10M
MIL
'~_-_---_-.,.'\
'~o~,I~
56 . I
56 PIP : i ( I [D36 Ilg' .
, .. TO IGNITION
RUN CIRCUIT r--581 -----l'r--..........- - - -
t f ,
~k ~
.-59 I
SAW , \ , 16 EDIS
~ ~ ~~
36 lGNONO 'au u <. ; MODULE
CASEDNO 3
58 ,NJ
:::
INJ ...."
Fe
BANK 2
59 CCOAIT

, 'NJEemAS 5 '"'"o
52 CANP <
" SS AfT
31 ISCBPA CONVERTER
"'"
I
1 21 41 21 VPWR
37
57 VPWR
CLUTCH OVERRIDE
AND SHIFT
SOLENOIDS
'"s-
~
co
(CCO.SS) CD
(AITONlY)
(I)
C
"0
"0
CD
3
-I
CD
::J
ALL RIGHTS RESERVED
r-
rn~~ G
AlC
CLUTCH A13583A .... <=
"" r-- -...
:r
c"'"
n
~
4.0L
EFI
AEROSTAR
2 810 R/LG Brake OnlOff BOO
4 11 DG/Y Engine rpm Sensor (+) RPMS (+)
6 398 BK/Y Vehicle Speed Sensor (-) VSS DIF (-)
9 695 BK/O Data Communications Link (-) DATA (-)
10 347 BK/Y AIC Cycling Switch ACCS
25 357 LG/P Air Charge Temperature. Sensor ACT
28 696 O/BK Data Communications Link (+) DATA (+)
30 199 LB/Y Clutch Interlock SWitch (MIT Only) CIS
30 199 LB/Y Neutral Drive Switch (A/T Only) NDS
36 324 Y/LG Spark Angle Width SAW
44 974 0 Octane Adjust OCT ADJ
..
54 321 GY/W WOT A/C Cut-Off WAC
Injector (Bank 1 - Controls Engine Cylinder Numbers 1. 2 and INJ BANK 1
58 96 T/O
3)
Injector (Bank 2 - Controls Engine Cylinder Numbers 4. 5 and INJ BANK 2
59 95 T/R
6)
Pin locations given for reference only. Probing 60 pin connector with - -
:1 000000000051 @OOOOOOOOOOO 41
DVOM probe will result in permanent damage to the pin connectors. 40 000000000031 0
300000000000 21
Always probe as directed. using the Breakout Box. 20 0000000000" 100000000000 1

ALL RIGHTS RESERVED
4.0L
EFI
RANGER/BRONCO II
4 11 DG/Y Engine rpm Sensor (+) RPMS (+)
9 96 T/O Data Communications Link (-) DATA (-)
10 198 T/Y A/C Cycling Switch ACCS
14 967 OB/O Mass Air Flow Sensor MAF
16 259 BK/O Ignition Ground fGN GNO
20 327 BK/O Case Ground CASE GND
28 95 T/R Data Communications Link (+) DATA (+)
36 324 Y/LG Spark Angle Width SAW
44 240 W/R Octane Adjust OCT ADJ
45 356 OB/LG Barometric Pressure Sensor BP
54 462 P WOT A/C Cut-Off WAC
56 363 BK/LBB Profile Ignition Pick-Up PIP
58 555 Injector (Bank 1 - Controls Engine Cylinder Numbers 1, 2, and
T 3) INJ BANK 1
59 556 Injector (Bank 2 - Controls Engine Cylinder Numbers 4, 5, and

W 6) I~J BANK 2
Pin locations given for reference only. Probing 60 pin connector with
soro -
00000000051 @ O O 000000000
-41
Always probe as directed, using the Breakout Box.
40 000000000031 0
300000000000 12
20 0000000000 100000000000 1'
11

ALL RIGHTS RESERVED
EECIV ~ Engine Supplement - Light Truck 1619
4.0L
Quick Test Codes and Code Definition MA
EFI
16 0 ~ Ignition Diagnostic Monitor (10M) signal not received
18 r ~ SAW circuit failure
18 c ~ Loss of 10M input to processor/10M circuit failure
21 or ~ Engine Coolant Temp (ECT) out of Self-Test range
22 orc ~ Barometric Pressure (BP) out of Self-Test range
24 or ~ Air Charge Temp (ACT) out of Self-Test range
26 or ~ Mass Air Flow (MAF) out of Self-Test range
45 c ~ Coil 1, 2, or 3 failure
-530c ~ TP circuit above maximum voltage
56 oc ~ MAF circuit above maximum voltage
66 c ~ MAF circuit below minimum voltage
67 c ~ Clutch Switch circuit failure
72 r ~ Insufficient MAF change during Dynamic Response Test
79 ~ A/C ON/Defrost ON during Self-Test
95 oc ~ Fuel Pump circuit open-ECA to motor ground
96 oc ~ Fuel Pump circuit open-battery to ECA

ALL RIGHTS RESERVED
CLUTCH INTERLOCK 10 10IGN
SWITCH BATIERY STARTSW
CLUTCH
.. .. j
MLP
ENG. SWITCH SENSOR HEATED ENGINE AIR MANIFOLD POWER
I VEHICLE EXHAUST GAS COOLANT THROTILE CHARGE ABSOLUTE VEHICLE STEERING
mf~ f;;';' ~~ i
HARNESS OXYGEN TEMP POSITION TEMP PRESSURE 4 x4 LOW EGR VALVE KNOCK SPEED PRESSURE
CONNEClUR (HEGO) (ECT) (TP) (ACT) (MAP) (4 x 4L) POSITION (EVP) SENSOR SENSOR SWITCH SELFTEST
ATE40D SENSOR SENSOR SENSOR SENSOR SENSOR SWITCH SENSOR (KS) (VSS) (PSPS, CONNECTOR
s~:~w.~Y-rR!4':" R I -
STARTER
RELAY
':"~ . , ~ !.~ c..- .
'1'li'.'O ' ;
o0
o
SELFTEST
INPUT
~13l9.0_.:,,~,v:::,v:n~_~======--:-:-:~ 12 4 x 4 LOW 27
(STI)
NOS AIT~ AlTE40DIOt8500) 7 46 46

2647
4625 46
4526
LED (E40D) 1 4t26 2,6
46
3
I 6
46 46
I 24 I TO
17
I
HEGOGND L=
IG~'J~N 48
HEGO OCIL LEO
4 x 4L (E40D) CIRCUIT
E~ 32~
COIL OVERORiVEV .~
TP
ACT
OCS
MAP
41
CANCEL
SWITCH (E40D)
~
10 KEY POWER
,
60PIN
204060
27-
EVP
KS
23 VSSDIF (+)
3 VSS'i5iFT-i
6
VREF
AT FUSE PANEL
ct
"CHECK
ENGINE"
26'PSPS LIGHT
(MIL)
24 SiGRTN
~:~~1
STO & Mli.
STI
~
__ >--------'""""-------,
t-__-,>--__, __-,
58o==l..:...._ _.....
58 INJ BANK 2 10 IGNITION
5~ 10M 22K OHMS RUN CIRCUIT
56 PIP
SPOUT

I : : ill 36
I--------;-", 10 IGNITION COIL
36 IGN GND .. TFI 1 2 3

----y . . . INJE~ORS
I \
16 CASE GND -,----- CONNEClUR

W~ - I m
42 AM2
11 A'M1
m
51 CCS
46--"
o
55 EVA 55 I I I t
<
ff.
53
53 I Rlldffil TRAN~~~SION I
1 21 41
3'~
52 .!.
VEHICLE
HARNESS m
38~ CONNEClUR ::J
CO
19~
S-
22.IE..
21.! -------- -, ,
CD
37 YE!YB.
57 ::i!?Y:!R
FtR
,
I
I
I 31
,I
I
I 33
37/57 I,
51
: ,I I en
c
8 FPM
, KAPWR
40~
""CD
60 PWR GND
3
-
10 ACCS CD
43~ ::J
LL TO/GN I
ALL RIGHTS RESERVED
r - : C OEM CYCLIC SWITCH START/RUN .. ' r-

IDLE ~WITCH PRESSURE CIRCUIT
(TJ~ ~.
-..
SPEED A13584A
"''4:)
TO BATTERY SWITCH
CONTROL AIR =so
BYPASS
AIR
IISCSPA)
MANAG 1
(TAB)
.... r-e -t
c
n
71:'
EEC-IV - Engine Supplement - Light Truck 1621
4.9L
EFI
FSERIES/BRONCO

2 511 LG Brake On/Off (E40D Only) BOO
3 679 GY/BK Vehicle Speed Sensor (+) VSS DIF (+)
4 11 T Ignition Diagnostic Module 10M
6 676 PK/O Vehicle Speed Sensor (-) VSS DIF (-)
7 354 LG/B Engine Coolant Temperature Sensor ECT
8 238 DG/Y Fuel Pump Monitor FPM
9 695 .SK/O Data Communications Link (-) (California Only) Data (-)
10 347 BK/Y A/C Clutch ACC
11 200 BR Air Management 2 (except E40D) AM2
12 784' LB/BK 4 x 4 Low Switch (E40D Only) 4 x 4L
16 259 BK/O Ignition Ground IGN GNO
17 658 PK/LG Self-Test Output and "CHECK ENGINE" Light STO and MIL
19 315 PIO Transmission Shift Solenoid # 2 (E40D Only) SS2
21 264 W/LB Idle Speed Control (Bypass Air) ISC- BPA
22 926 LB/O Fuel Pump FS
23 99 LG/B Knock Sensor KS
24 330 Y/LB Power Steering Pressure Switch PSPS
25 310 G/Y Air Charge Temperature Sensor ACT
26 351 BR/W Reference Voltage VREF
28 696 O/BL Data Communications Link (+) (California Only) Data (+)
29 74 GY/LB Heated Exhaust Gas Oxygen Sensor HEGO
30 481 GY/Y Neutral Drive Switch (C6 A/T Only) NOS
30 199 LB/Y Manual Lever Position Sensor (E40D Only) MLP
31 101 GY/Y Canister Purge Solenoid (except E40D) CANP
32 911 W/LG Overdrive Cancel Indicator Light (E400 Only) OCIL
33 360 BR/PK EGR Vacuum Regulator Solenoid EVR
(Continued)

ALL RIGHTS RESERVED
16-22 EEC-IV - Engine Supplement - Light Truck !
4.9L
EFI
F-SE.RIES/BRONCO

36 929 PK Spark Output SPOUT
37 361 A Electronic Pressure Control Power/Vehicle Power EPCPWA/VPWA
38 925 W/Y Electronic Pressure Control Solenoid (E400 Only) EPC
40 570 BK/LG Power Ground PWA GND
41 224 T/W Overdrive Cancel Switch (E40D Only) OCS
42 923 O/BK Transmission Oil Temperature (E400 Only) TOT
43 348 LG/P A/C Demand ACO
45 358 LG/BK Manifold Absolute Pressure MAP
46 359 GY/A Signal Aeturn SIG ATN
47 355 GY/W Throttle Position Sensor TP
48 209 W/P Self-Test Input STI
49 89 0 Heated Exhaust Oxygen Ground HEGO GNO
51 190 W/O Air Management 1 AM1
52 562 LB Transmission Shift Solenoid # 1 (E40D Only) SS1
53 480 PlY Converter Clutch Control Solenoid (E400 Only) CCC
55 924 BA/O Converter Coast Solenoid (E400 Only) CCS
57 361 A Electronic Pressure Control Power/Vehicle Power EPCPWA/VPWR
58 555 T Injector Bank 1 (Controls Engine Cylinder Numbers 1, 3, and 5) INJ BANK 1
59 556 W Injector Bank 2 (Controls Engine Cylinder Numbers 2, 4 and 6) INJ BANK 2
60 570 BK/W Power Ground PWA GNO

connector with OVOM probe will result in permanent damage
-
r000000000051 500000000000
-
141
to the pin connectors. Always probe as directed, using the 6:1
40 0000000 00031@300000000000 12 1
Breakout Box. 20 0000000000
11
100000000000 1 I

ALL RIGHTS RESERVED
4.9L
EFI
E-SERIES
Pin . Circuit Wire Color Application Abbreviations

6 563 O/Y Vehicle Speed Sensor (-) VSS DIF (-) ,
9 695 BK/O Data Communications Link (-) (California Only) Data (-)
10 347 BK/Y A/C Cycling Switch ACCS
11 200 W/BK Air Management 2 AM2
19 315 DG/P Transmission Shift SolenC?id # 2 (E40D Only)
. SS2
~

..
"./
23 99 LG/B Knock Sensor KS

24 330 Y/LB Power Steering Pressure Switch . PSPS
.25 310 Y/R Air Charge Temperature Sensor ACT
28 696 O/BK Data Communications Link (+) (California Only) Data (+)
30 912 BR/W Neutral Drive Switch NOS
30 912 LB/W Manual Lever Position Sensor (E40D Only) MLP
32 911 LG/W Overdrive Cancel Indicator Light (E40D Only) OCIL
33 360 DG EGR Vacuum Regulator (Solenoid) EVA
, ..
37 361 R Electronic Pressure Control Power/Vehicle Power EPCPWR/VPWR
38 199 LB/Y Electronic Pressure Control-Solenoid (E40D Only) EPC
'-.
.-
41 224 T/LB Overdrive Cancel Switch (E40D Only) OCS
42 923 O/BK Transmission Oil Temperature Sensor (E40D Only) TOT
(Continued)

ALL RIGHTS RESERVED
4.9L
EFI
ESERIES

45 356 DB/LG Manifold Absolute Pressure MAP
49 89 0 Heated Exhaust Gas Oxygen Ground HEGO GND
51 190 W/R Air Management 1 AM1
52 237 O/Y Transmission Shift Solenoid # 1 (E40D Only) SS1
53 480 PlY Converter Clutch Control Solenoid (E40D Only) CCC
55 924 BR Converter Coast Solenoid (E40D Only) CCS
58 96 T/O Injector Bank 1 (Controls Engine Cyl. Nos. 1, 3, and 5) INJ BANK 1
59 95 T/R Injector Bank 2 (Controls Engine Cyl. Nos. 2, 4, and 6) INJ BANK 2

-
000000000051 @OOOOOOOOOOO
0
- 41
to the pin connectors. Always probe as directed, using the 40
60,1 000000000031 300000000000 21
Breakout Box. 20 0000000000 100000000000 1
"

ALL RIGHTS RESERVED
EEC-IV.- Engine Supplement - Light Truck 16-25
4.9L
EFI
18 c ~ Loss of 10M input to processor/SPOUT circuit grounded
21 or ~ Engine Cooling Temperature (ECT) sensor out of Self-Test range
22 orc ~ Manifold Absolute Pressure (MAP) sensor out of Self-Test range
23 or ~ Throttle Position (TP) sensor out of Self-Test range
24 or ~ Air Charge Temperature (ACT) sensor out of Self-Test range
26 or ~ Transmission Oil Temperature (TOT) sensor out of Self-Test range (E400)
33 rc ~ EGA valve opening not detected
44 r ~ Thermactor air system inoperative
45 r ~ Thermactor air upstream during Self-Test
46 r ~ Thermactor air not bypassed during Self-Test
47 0 ~ 4 x 4 switch is closed (E400)
49 c ~ 1-2 shift error (E400)
53 oc ~ TP sensor above maximum voltage
56 oc ~ TOT indicated - 40F/circuit open (E400)
59 c ~ 2-3 shift error (E400)
61 orc ~ ECT indicated 254F/circuit grounded
62 c ~ Converter clutch error (E400)
63 orc ~ TP circuit below minimum voltage
64 orc ~ ACT indicated 254F/circuit grounded
65 r ~ Overdrive Cancel Switch (OCS) not changing state (E400)
66 oc ~ TOT indicated 290F/circuit grounded (E400)
(Continued)

ALL RIGHTS RESERVED
4.9L
EFI

67 oc ~ Manual Lever Position (MlP) sensor out of range/A/C on (E40D)
69 c ~ 3-4 shift error (E40D)
74 r ~ Brake On/Off (BOO) circuit open/not actuated during SelfTest
81 0 ~ Air Management 2 (AM2) circuit failure
91 0 ~ Shift Solenoid 1 (SS1) circuit failure (E40D)
93 0 ~ Coast Clutch Solenoid (CCS) circuit failure (E40D)
94 0 ~ Converter Clutch Control (CCC) solenoid circuit failure (E40D)
95 oc ~ Fuel pump circuit open - ECA to motor ground
96 oc ~ Fuel pump circuit open - battery to ECA
97 0 ~ Overdrive Cancel Indicator Light (OCll) circuit failure (E40D)
98 0 ~ Electronic Pressure Control (EPC) driver open in ECA (E40D)
99 oc ~ Electronic Pressure Control (EPC) circuit failure (E40D)
CODES NOT LISTED ~ Services codes displayed are not applicable to the vehicle being tested

ALL RIGHTS RESERVED
m
"'0
TO
BAITERY
TO IGN. START SW. m
~
:2
I
~ m
n....
.......
:::J
CO
HEATED ENGINE AIR MANIFOLD POWER
:i"
CD
EXHAUST GAS COOLANT THROTTLE CHARGE
OXYGEN TEMP POSITION TEMP
ABSOLUTE '.
PRESSURE KNOCK
EGR VALVE
POSITON
STEERING VEHICLE
PRESSURE SPEED n rn
, ~"'fmr ~1()
HEGO
GROUND
(HEGQ)
SENSOR
(ECT)
SENSOR
(TP) (ACT)
SENSOR SENSOR
(MAP)
SENSOR
SENSOR
(KS)
(EVP)
SENSOR
SWITCH
(PSPS)
SENSOR
(VSS)
SELFTEST
CONNECTOR I I C
~
C
"'0
~
"'0
~~~ ~ J
SELF-TEST
INPUT
(STI)
en
n
CD
3
-I
.. u 1'0 PWR . CD
HEGO 49 GND .
:r' ::J
E~T 4~2647 4iY~6
i~
4t26 4f 24 ~
a
29 746 T2 5 2 :}
1 1i6
r-
SO-PIN
20 40 SO
48
....C....
n -...
cO'
=r
~
c(')
~
4S~
17 STO & MIL
48 .!.L
4 10M 22K OHMS I TO IGNITION
RUN CIRCUIT
5S .f!E.
36 ..f.Q!ll
IGN GND
;~ CASE GND
22 FP
\
c. --------1
I \ ,
:::i-
':'
L,'6 4
TO IGNITION COIL
58~
59~
~~ ~~~
" AM'
I I I
1 21 41
~~
ISC
VPWR f 21""h 33
;d,--37/57 I,
51'1
,I I ~
~~ ::::r:t:= ~
57 VPWR IDLE
SPEED Ric!'( 'iF5.Ci' TO
CONTROL EGR ~ ~ FUEL
BYPASS VACUUM AIR AIR PUMP
AIR REGULATOR
FPM (ISCBPA) (EVR)
KAPWR
40~
SO PWR GND
,o~ ,10~
TO BATTERY -- - AlC-"
OEM CYCLIC
~ L....++--J
AlC
~
SWITCH PRESSURE CLUTCH TO
SWITCH IGNITION
SWITCH
m!J1
START/RUN
CIRCUIT
NOTE: WIRING SCHEMATIC SHOWS PIN OUT LOOKING INTO HARNESS CONNECTOR A913o-
ALL RIGHTS RESERVED
~o
.... r-e ...
0)
N
.....
5.0L
EFI
FSERIES/BRONCO

4 11 T/Y Ignition Diagnostic Monitor 10M
7 354 LG/R Engine Coolant Temperature Sensor ECT
11 200 BR Air Management 2 AM2
16 259 0 Ignition Ground IGN GND
21 264 W/LB Idle Speed Control (Bypass Air) ISC-BPA
25 743 GY Air Charge Temperature Sensor ACT
29 74 GY/LB Heated Exhaust Oxygen Sensor HEGO
30 199 LB/Y Neutral Drive Switch NOS
40 570 BK/W Power Ground PWR GND
46 359 GY/R Signal Return SIG RTN
48 209 'W/P Self-Test Input STI
49 89 0 Heated Exhaust Oxygen Ground HEGO GND
56 395 GY/O Profile Ignition Pick-Up PIP
58 555 T Injector (Bank 1- Controls Engine Cylinder Numbers 1, 4, 5 and 8) INJ BANK 1
59 556 W Injector (Bank 2 - Controls Engine Cylinder Numbers 2, 3, 6 and 7) INJ BANK 2

connector with DVOM probe will result in permanent damage .Of -
0 00000000051 @ O O 0000000
0
- 00
1 41
to the pin connectors. Always probe as directed, using the 40 000000000031 300000000000 12 1
Breakout Box. 20 .... 0000000000 100000000000 1 1
"

ALL RIGHTS RESERVED
, 5.0L
EEC-IV Module- Connector Pin Usage
EFI
ESERIES

6 563 O/Y Vehicle Speed Sensor( -) VSS DIF( -)
~

20 57 BK Case 'Ground CASE GND
23 99 LG/BK Knock Sensor KS
25 310 Y/R Air Charge Temperature Sensor ACT
30 912 LB/W Neutral Drive Switch NOS
33 360 DG EGR Vacuum Regulator Solenoid EVR
37 361 R Vehicle -Power VPWR
45 356 DB/LG Manifold-Absolute Pressure MAP
Injector (Bank 1 - Controls Engine CyJ. Numbers 1, 4, 5 INJ BANK 1
58 96 T/O
and 8)
95 Injector (Bank ,2 - Controls Engine Cyl. Numbers 2. 3. 6 INJ BANK 2
59 T/R
and 7)

-
:(000000000051 @OOOOOOOOOOO
- 41
to the pin connectors. ~Iways probe as directed. using the 40 000000000031 0 300000POOOOO 21
Breakout Box. 20 0000000000" 100000000000 1

ALL RIGHTS RESERVED
,
5.0L
EFI
18 c ~ Loss of 10M input to Processor/SPOUT circuit grounded
19 0 ~ Failure in ECA internal voltage -
21 or ~ Engine Coolant Temperature (ECT) out of Self-Test range
25 r ~ Knock not sensed during Dynamic Response Test
31 orc ~ EGR Valve Position (EVP) circuit below minimum voltage
34 orc ~ EVP voltage is above closed limit
35 orc ~ EVP circuit above maximum vortage
44 r - ~ Thermactor air system inoperative
54
61
oc
oc
~ ACT indicated - 40F/circuit open
ECT indicated 254F/circuit grounded
-
~
67 0 ~ Neutral Drive Switch (NOS) circuit open/A/e ON
77 r ~ Operator Error (Dynamic Response/Cylinder Balance Tests)
84
87
0
oc
~
EGR Vacuum Regulator (EVR) circuit failure
Primary Fuel pump circuit failure
95 -oc ~ Fuel Pump circuit open - ECA to motor ground
KEY: 0 = Key On Engine Off (KOEO) r = Engine Running (ER) .c = Continuous Memory

ALL RIGHTS RESERVED
m
m
ClUTCHINTERlOCK
SWITCH
TO
BATTERY 4x4LOW o
CLUTCH
ENG. SWITCH
I
MLP
SENSOR
VEHICLE
HEATED ENGINE AIR
EXHAUST GAS COOLANT THROTTLE CHARGE
MANIFOLD
ABSOLUTE
(4 x 4L)
SWITCH
TO 'TOUCH
DRIVE" EGR VALVE VEHICLE
rn
..... <
I
~
.....n
HARNESS OXYGEN TEMP POSITION TEMP PRESSURE POSITION SPEED
MODULE
m
TOIGN
CONNECTOR
ATE40D
(HEGO)
SENSOR
(ECT)
SENSOR
(TP) (ACT)
SENSOR SENSOR
(MAP)
SENSOR
(BRONCO
OPTION)
(EVP)
SENSOR
(VSS)
SENSOR
SELF TEST
CONNECTOR n.... ~
co
~l::'---' ~o
~~
START SW
:i"
rt ~
1
SELFTEST
'~PO~E~
~ ,,),
r'.'~r
, INPUT CD
o
':"l!~{
(STI)
tn
AfT C6 UI8500
30
GND
o ~ .....
C c
'tJ
(E'D~ ,~J
4 x 4 LOW
~ 'tJ
NDS
HEGOGND
GVW AfT E40D (0/8500)
I , " 11 126
LED I, 46
TO
IGNITION
17 48
(J)
n
CD
3
-
HEGO 29....J 46 146 125 RUN
4x4L il 147 26 CIRCUIT CD
7 ECT
32 OCIL 32-4+1f------_+_( ~
~
~
I
47 TP
25~
I
~ a r-
6o-PIN
41 0CS
45 MAP
27 EVP
3 VSS DIF (+)

VSS DIF (.)
41 II I
TO KEY POWER
AT FUSE PANEL
t ~~~~~~, ~
LIGHT
(MIL)
.......
C
n -
cO
=r
.,-4
c
n
20 40 60 6 -- ~
26 VREF
46 SIG RTN
17~
48 _ST_I_ _
58~ 58 I
59~
IDM 22K OHMS
5: PIP ..... --------"7, ..
TO IGNITION
RUN CIRCUIT'
36 SPOUT : : \
16 IGN GND \ TO IGNITION COIL
20 CASE GND <... -------
3
"~~
42 TOT 1 2 INJECTORS 7 8
11 AM2 ,
51 AM1
55 CCS
33 EVR
~~ ~ 59--+----J
31CANP TRANSMISSION
1 21 41
551 VEHICLE
1-....---58 + I
~~ ~~
: SS2 CONNECTOR
22 _F~P:-- ---4 ~ _ _---' _

22
21 ISC
37 VPWR
57 VPWR I 37/57 37157 - - - - <....- - - - ,
FPM 31 33 5,1
KAPWR
40 PWR GND
60 PWR GND
10 ACCS
. rn g,
SI~~~D ~ IGN;~ON - .,.,
....
ALL RIGHTS RESERVED
CONTROL CANISTER EGR -- SWITCH QC)

BYPASS PURGE VACUUM AIR AIR START/RUN A 11511C
r-
AIR
(ISCBPA,
SOLENOID
(CANP)
REGULATOR
(EVR)
MANAG 1
/TAB I
MANAG 2
ITAD)
CIRCUIT ~
.
0)
Cot)
~
5.8L
EFI
FSERIES/BRONCO

'4 11 T/Y Ignition Diagnostic Monitor 10M
11 200 BR Air Management 2 AM2
12 784 LB/BK 4 x 4 Low Switch (E40D Only) 4 x 4L
19 315 P/O Transmission Shift Solenoid # 2 (E40D Only) SS2
21 264 LB/W Idle Speed Control (Bypass Air) ISC-BPA
30 481 GY/Y Neutral Drive Switch (C6 A/T Only) NOS
30 199 "LB/Y Manual Lever Position Sensor (E40D Only) MLP
32 911 W/LG Overdrive Cancel Indicator Light (E40D Only) OCIL
(Continued)

ALL RIGHTS RESERVED
5.8L
EFI
F-SERIES/BRONCO

37 361 A Electronic Pressure Control Power/Vehicle Power EPCPWA/VPWA
38 925 W/Y Electronic Pressure Control Solenoid (E40D Only) EPC
42 923 O/BK Transmission Oil Temperature (E40D Only) . TOT
48 209 W/P Self-Test Input \
STI
55 924 BA/O Converter Coast Solenoid (E40D Only) CCS
57 361 A Electronic Pressure Control Power/Vehicle Power EPCPWA/VPWR
58 555 T Injector Bank l' (Controls Engine Cylinder Numbers 1, 4, 5 and 8) INJ BANK 1
59 556 W Injector Bank 2 (Controls Engine Cylinder Numbers 2, 3, 6 and 7) INJ BANK 2
60 570 BK/W Power Ground PWA GND

...
'000000000051 @OOOOOOOOOOO 141
..
to the pin connectors. Always probe as directed, using the 6:1
40 000000000C?31 0
300000000000 b1
Breakout Box. 20 0000000000
11
100000000000 1 I

ALL RIGHTS RESERVED
1634 EEC-IV - Engine Supplement - Light Truck
5.8L
EFI
ESERIES
Pin Circuit Wire Color Application ._ Abbreviations

8 238 O/lB Fuel Pump Monitor FPM
18 223 T/lG Inferred Mileage Sensor (49 States) .IMS
19 315 OG/P Transmission Shift Solenoid # 2 (E40D Only) SS2
22 97 T/lG Fuel Pump FP
26 351 O/W Reference Voltage VAEF
27 352 BA/LG EGA Valve Position Sensor EVP
29 94 OG/P Heated Exhaust Gas Oxygen Sensor HEGO
30 912 BR/W Neutral Drive Switch NOS
30 912 LB/W Manual lever Position Sensor (E40D Only) 'MlP
32 911 LG/W Overdrive Cancel Indicator Light (E40D Only) OCll
33 360 DG EGR Vacuum RegUlator Solenoid EVR
36 324 Y/lG Spark Output SPOUT
37 361 A Electronic Pressure Control Power/Vehicle Power EPCPWR/VPWA
38 199 LB/Y Electronic Pressure Control Solenoid (E40D Only) EPC
41 224 T/LB Overdrive Cancel Switch (E40D Only) OCS
(Continued)

ALL RIGHTS RESERVED
5.8L
EFI
E-SERIES
p,ln Circuit Wire Color Application Abbreviations

52 237 O/y Transmission Shift Solenoid # 1 (E40D Only) SS1
55 924 BR Converter Coast Sqlenoid (E40D Only) CCS
58 96 T/O Injector Bank 1 (Controls Engine Cyl. Nos. 1, 4, 5, 'and 8) INJ BANK 1
59 95 . T/R Injector Bank 2 (Controls Engine Cyl. Nos. 2, 3, 6, and 7) INJ BANK 2

-
60 roooooOOOOOS1 500000000000
- 41
to the pin connectors. Always probe as directed, using the 401 00000000003'@300000000000 21
Breakout Box. 20 0000000000 11 100000000000 1

ALL RIGHTS RESERVED
5.8L
EFI
18 c ~ Loss of IDM input to processor/SPOUT circuit grounded
21 or ~ Engine Cooling Temperature (ECT) sensor out of Self-Test range
22 orc ~ Manifold Absolute Pressure (MAP) sensor out of Self-Test range
23 or ~ Throttle Position (TP) sensor out of Self-Test range
24 or ~ Air Charge Temperature (ACT) sensor out of Self-Test range
26 or ~ Transmission Oil Temperature (TOT) sensor out of Self-rest range (E40D)
33
34
rc
orc
~
~
EGR valve opening not detected
EVP voltage above closed limit
.
44 r ~ Thermactor air system inoperative
47 0 ~ 4 x 4 switch is closed (E40D)
51 oc ~ ECT indicated - 40F/ circuit open
53 oc ~ TP above maximum -voltage
56 oc ~ TOT indicated - 40F/ circuit open (E40D)
62 c ~ Converter clutch error (E40D)
63 oc ~ TP circuit below min. voltage
65 r ~ Overdrive Cancel Switch (OCS) not changing state (E40D)
66 oc ~ TOT indicated 290F/circuit grounded (E40D)
67 0 ~ Neutral Drive Switch (NDS) circuit open; AIC ON (Manual) "
(Continued)

ALL RIGHTS RESERVED
EEC-IV - Engine Supplement ~ Light Truck 16-37
5.8L
EFI

67
69
oc
c
.-.- MlP sensor out of range; A/C ON (E40D)
3-4 shift error (E40D)
72 r .- Insufficient MAP change during Dynamic Response Test
73
74
r
r
.-.- Insufficient TP change during Dynamic Response Test
Brake On/Off (BOO) circuit open - not actuated during Self-Test
77 r .- Operator error Dynamic Response Test
.-.-.-
81 0 Air Management 2 (AM2) circuit failure
82 0 Air Management 1 (AM 1) circuit failure
84 0 EGR Vacuum Regulator (EVR) circuit failure
85
87
0
oc
.-.- Canister Purge (CANP) circuit failure
Primary fuel pump circuit failure
91 0 .- Shift Solenoid 1 (SS1) circuit failure (E40D)
92
93
94
0
0
0
.-.-.- Shift Solenoid 2 (SS2) circuit failure (E40D)
Coast Clutch Solenoid (CCS) circuit failure (E40D)
Converter Clutch Control (CCC) solenoid circuit failure (E40D)
95
96
97
oc
oc
0
.-.-.- Fuel Pump circuit open - ECA to motor around
Fuel Pump circuit open - battery to ECA
Overdrive Cancel Indicator Light (OCll) circuit failure (E40D)
98
98
99
0
r
oc
.-.-.- Electronic Pressure Control (EPC) driver failure in processor (E40D)
Hard fault present
Electronic Pressure Control (EPC) circuit failure (E40D)
NO CODES .- Unable to initiate Self-Test or unable to output Self-Test codes
CODES NOT LISTED .- Services codes displayed are not applicable to the vehicle being tested

ALL RIGHTS RESERVED
~
en

w
CD
m
....
a....
FUEL
INJECTION MANUAL VEHICLE
R)
4x4 PUMP LEVER BAROMETRIC LEVER SPEED
LOW (4 x4L) POSITION (FIPL) PRESSURE (BP) POSITION (MLP) SENSOR
SWITCH SENSOR SENSOR SENSOR (VSS) SELF-TEST
CONNECTOR
lb!J ~,
n
~~
<--"
12~
4)( 4 LOW LED

IllLl.....1..l1JJ,
o
f
"1 ,\
'
o
SELF_TEST
INPUT
(STI)
....C
2~
32.29!:!IM!h
OVERDRIVE CANCEL ,16L... 46 I l=:!J
(I)
cr
14,5 30 46 6
,
- --
INDICAlOR LIGHT
(OCIL)
26
1,6 0 n
41
L41 --o ,If
47 17
8 :r
R)
a
OVERDRIVE
CANCEL 10 KEY POWER
SWITCH AT
47
FIPL
BP
(OCS) FUSE PANEL
a
....
60-PIN
45
n
20 40 60 VRFF
26
-MLP
~
30
VSS OJF (+)
3
VSS OIF (0)
6
SIGRTN
46
S10
17
STI
48
lOT
7
44
36
RPMSI-)
TAC
4';:":-::~~
) \CHOMETER
I
....JI
~
ENGINE
SENSOR
1
20~ m
~ E400 m
o
~
CCS TRANSMISSION
55 VEHICLE
53
"SSI
CCC
55 ~
HARNESS
CONNECTOR
<:
~
36
m3 I
W m
"E""?WR
37 VPWR
35 19 35 ~
12141
57 VPWR T I 57
I". co
5'
CD
1
37,57
en
c
'C
1 KAPWR "'C
40~ Ci'
60~ 3
10~
10 BATTERY..- " -
-1~
~ CL~~CH-= 10
Orn
-,..
CD
~
I
ALL RIGHTS RESERVED
IGNITION
AlC OEM CYCLIC SWITCH
.... ~ -..J
-
cO'
SWITCH PRESSURE START/RUN
~O~
SWITCH CIRCUIT ~
NOTE: WIRING SCHEMATIC SHOWS PIN OUT LOOKING INTO HARNESS CONNECTOR A12786-B
!.Or- .,
-4
c
n
~
7.3L
EEC-IV Module Connector Pin Usage E40D
DIESEL
F-SERIES

4 11 T/Y Engine RPM Sensor (+) RPMS (+)
7 923 O/BK Transmission Oil Temperature Sensor TOT
12 784 LB/BK 4x 4 Low Switch 4 x 4L
17 658 PK/LG Self-Test Output STO
19 315 P/O Transmission Shift Solenoid #2 SS2
30 199 LB/Y Manual Lever Position Sensor MLP
Overdrive Cancel Indicator Light OCIL
32 911 LG/W
Transmission Malfunction Indicator Light TMIL
35 912 W/R Electronic Pressure Control Power EPCPWR
36 648 W/PK Tachometer (Spark Output) TAC
38 925 W/Y Electronic Pressure Control EPC
41 224 T/W Overdrive Cancel Switch OCS
44 644 DG/N Engine RPM Sensor (-) RPMS (-)
47 355 GY/W Fuel Injection Pump Lever Sensor FIPL
52 237 O/Y Transmission Shift Solenoid # 1 SS1
53 480 PlY Converter Clutch Control Solenoid CCC
55 924 BRIO Converter Coast Solenoid CCS
.60 570 BK/W Power Ground PWR GND
- -
r
connector with DVOM probe will result in permanent damage 000000000051 ( 0 0 0 0 0 0 0 0 0 0 0 0
to the pin connectors. Always probe as directed, using the 60,1 000000000031
40 0300000000000 21
Breakout Box. 20 0000000000 100000000000 1

"

ALL RIGHTS RESERVED
7.3L
EEC-IV Module Connector Pin Usage E40D
DIESEL
ESERIES

4 349 DB Engine RPM Sensor (+) RPMS (+)
7 923 O/BK Transmission Oil Temperature Sensor TOT
17 201 T/R Self-Test Output STO
19 315 DG/P Transmission Shift Solenoid #2 SS2
30 912 LB/W Manual Lever Position Sensor MLP
Overdrive Cancel Indicator Light OCIL
32 911 LG/W
Transmission Malfunction Indicator Light TMIL
35 925 Y/W Electronic Pressure Control Power EPCPWR
36 648 R/LB Tachometer (Spark Output) TAC
38 199 LB/Y Electronic Pressure Control EPC
41 224 T/LB Overdrive Cancel Switch OCS
44 60 BK/LG Engine RPM Sensor( - ) RPMS( -)
47 355 DG/LG Fuel Injection Pump Lever Sensor FIPL
52 237 O/Y Transmission Shift Solenoid # 1 SS1
53 480 PlY Converter Clutch Control Solenoid CCC
55 924 BR Converter Coast Solenoid CCS

-
SOfOOOOOOOOOO.' @"OOOOOOOOOO
- 1 41
to the pin connectors. Always probe as directed, using th.e 40 000000000031 0
300000000000 12 1
Breakout Box. 20 \.. 0000000000 11 100000000000 1 I

ALL RIGHTS RESERVED
7.3L
Quick Test Codes and Code Definition 'E40D
DIESEL
SERVICE~ CODE SERVICE CODE DEFINITION
1.1 orc ~ System PASS
14 c ~ Engine rpm sensor (rpms) circuit fault
22 orc ~ Barometric Pressure (BP) out of Self-Test range
23 or ~ Fuel Injection Pump lever (FIPl) out of Self-Test range
26 c ~ Transmission Oil Temp (TOT) out of Self-Test range
47 0 ~ 4 x 4 switch is closed
49 c ~ 1-2 Shift error
53 oc ~ Fuel Injection Pump lever (FIPl) circuit above maximum voltage
56 oc ~ Transmission Oil Temp (TOT) indicated - 40F/circuit open
59 c ~ 2-3. Shift error
62 c ~ Converter Clutch error
63 oc ~ Fuel Injection Pump lever (FIPl) circuit below minimum voltage
65 r ~ Overdrive Cancel Switch (OCS) circuit did not change states
66 oc ~ Transmission Oil Temp (TOT) indicated 290F/circuit grounded
67 oc ~ Manual lever Position (MlP) sensor out of range/ AIC ON
69 c ~ 3-4 Shift error
74 r ~ Brake On/Off (BOO) circuit open/not actuated during Self-Test
91 0 ~ Shift Solenoid 1 (SS1) circuit failure
92 0 ~ Shift Solenoid 2 (SS2) circuit failure
93 0 ~ Coast Clutch Solenoid (CCS) circuit failure
94 Converter Clutch Control (CCC) Solenoid circuit failure
.
0 ~
97 0 ~ Overdrive Cancel Indicator Light (OCll) circuit failure
98 0 ~ Electronic Pressure Control (EPC) driver open in ECA
99 oc ~ Electronic Pressure Control (EPC) circuit failure

ALL RIGHTS RESERVED
.
"""
CJ)

I ll,)
CLUTCH-INTERLOCK
SWITCH
TO
BATIERY
TO IGN. START SW.
....
rrJ
~
CLUTCH
n.... ,
ENG. SWITCH
I
MLP
SENSOR
HEATED
GASH~~EN C~LANT POSI~ION

EXHAUST GINE THROTTLE
AIR
~;~
CHARGE
M:~6i~~~
~RESSURE EGR VALVE
S~~~6R
POSITION VEHICLE
...
TO IGN VEHICLE (MAP)R
4.4 SPEED
n
'~~~_ii~,'
SWITCH SENSOR
....
START SW HARNESS ( SOR TEMP (ECT) (T ) SENSOR SENSO
(4.4 L) (VSS)
CONNECTOR
ATE40D
SELF-TEST
CONNECTOR C
SELFTEST
rn
AlTC6 UI8500
GVW
~GO
---- ---- I
t!E"~v~vv~,~W=-=-=-=--=----. l"o
======= I"ttl'" II':I
,,"",'"11146126 I I 1215 126 126
46 17
INPUT
(STI)
22
n
:r
~
~~'~ I I II I II I II I I I 32 TO IGNITION
RUN a
::':~ I I II I I II I II O~~IVE ....
C
CANCEL
SWITCH TO KEY POWER
(E40D) AT FUSE PANEL
n
~T~
6o-PIN
.... , , . ENGINE""
"CHECK
20 40 60
, 46 I LIGHT
(MIL)
'''" C""',, I
INJ BANK 2
1===58 59 T , ,
t i
I
IUM "'" ... " ..... " " -.l'
~~~ETGND~ TO IGNITION COIL(-)
IGN GND ,: CON~;~TOR TO IGNITION

PIP-A . ' START
' . ,. i 46
m
m
o
E40D
TRANSMISSION
;:
1 21 41
VEHICLE
HARNESS I
CONNECTOR m
::s
co
S'
CD
en
.. ~.~ ~ ~ ~
40
c
r::'" ~
, "0
~"
'W,,'O 21 31
"", W. "0
TO
CD
c",,, cc"'" ''''''0' 3
-
IDLE SWITCH PRESSURE SWITCH FUEL
SPEED PUMP CD
CONTROL
BYPASS CANISTER PURGE
AIR
MANAG 1
TO
SWITCH START/RUN
::s
BATIERY CIRCUIT
AIR SOLENOID (AM1)
IISC-BPA) (CANP) I
--:I r-
...--n c.nr- ..-

ALL RIGHTS RESERVED
NOTE: WIRING SCHEMATIC SHOWS PIN OUT LOOKING INTO HARNESS CONNECTOR A9987-D
rrJ cO'
=r
-4
c
n
~
7.5L
EFI
FSERIES

3 679 GY/BK Vehicle Speed Sensor (+) (E40D Only) VSS DIF (+)
4 11 T/Y Ignition Diagnostic Monitor 10M
6 676 PK/O Vehicle Speed Sensor (-) (E40D) VSS DIF (-)
12 784 LB/BK 4 x 4 Low Switch (E40D Only) 4 x 4L
19 315 P/O Transmission Shift Solenoid # 2 (E40D Only) SS2
21 264 W/LB, Idle Speed Control (Bypass Air) ISC-BPA
30 481 GY/Y Neutral Drive Switch NOS
30 199 LB/Y Manual Lever Position Sensor (E40D Only) MLP
32 911 W/LG Overdrive Cancel Indicator Light (E40D Only) OCIL
33 360 BR/PK EGR Vacuum Regulator (Solenoid) EVR
36 929 PK Spark Output -SPOUT
38 925 W/Y Electronic Pressure Control Solenoid (E40D Only) EPC
(Continued)

ALL RIGHTS RESERVED
7.5L
EFI
FSERIES
Pin Circult Wire Color Application Abbreviations

55 924 BR/O Converter Coast Solenoid (E40D Only) CCS
58 555 T Injector (Bank 1 Controls Engine Cylinder Numbers 1, 4, 5 and 8) INJ BANK 1
59 556 W Injector (Bank 2 Controls Engine Cylinder Numbers 2, 3, 6 and 7) INJ BANK 2

-
60 '000000000051 500000000000
- 41
1
to the pin connectors. Always probe as directed, using the 40 000000000031@300000000000 121
Breakout Box. 20 I 0 000000 000 10 0 00 00 000 0 0 1 1
11

ALL RIGHTS RESERVED
EEC-IV - Engine Supplement ~ Light Truck 16-45
7.5L
EFI
E-SERIES

2 511 LG Brake OnlOff BOO
17 201 T/R Self-Test Output and "CHECK ENGINE" Light STO/MIL
19 315 DG/P Transmission Shift Solenoid # 2 (E40D Only) SS2
22 97 T/LG ",' Fuel Pump FP
30 912 LB/W Manuai Lever Position Se_nsor (E40D Only) MLP
32 911 LG/W Overdrive Cancel Ihdicator Light (E40D Only) OCIL
33 360 DG EGR Vacuum Regulator Solenoid EVR
38 199 LB/Y Electronic Pressure Control Solenoid (E40D Only) EPC
41 224 T/LB Overdrive Cancel Switch OCS
(Continued)

ALL RIGHTS RESERVED
7.5L
EFI
E-SERIES

52 237 OIY Transmission Shift Solenoid # 1 (E40D Only) SS1
53 480 PlY Converter Clutch Control Solenoid (E40D Only) tcc
55 924 BR Converter Coast Solenoid (E40D Only) CCS
Injector (Bank 1 Controls Engine Cylinder Numbers 1, 4,
58 96 TIO INJ BANK 1
5 and 8)
Injector (Bank 2 Controls Engine Cylinder Numbers 2, 3,
59 95 T/R INJ BANK 2
6 and 7)

-
60 '000000000051
-
500000000000 41
to the pin connectors. Always probe as directed, using the 40,1 0000000 00031@3000000000 00 21
Breakout Box. 20 0 000000 000 10 000 00 000 00 1
11

ALL RIGHTS RESERVED
7.5L
Quick Test Codes and Code Definition'
EFI
11 orc ~ System PASS /

15 0 ~ ECA Read Only Memory (ROM) test ,fail~d
18 c ~ SPOUT circuit grounded
21 or ~ Engine Cooling Temperature (ECT) sensor input is out of Self-Test range
22 orc ~ Manifold Absolute Pressure (MAP) sensor input is out of Self-Test range
23 or ~ Throttle Position (TP) sensor input is out of Self-Test range
24 or ~ Air Charge Temperature (ACT) sensor input is' out of Self-Test range
26 or ~ Transmission Oil Temperature (TOT) sensor input is out of Self-Test range (E40D)
41 r ~ HEGO sensor circuit indicates system lean '-

44 r ~ Thermactor ai,r system inoperative
47 0 ~ 4 x 4 switch is closed (E400)
49 c ,~ 1-2 shift error (E40D)
53 oc ~ TP above maximum voltage
56 oc ~ TOT indicated - 40F/circuit open (E400)
59 c .~ 2-3 shift error (E400) I

62 c ~ Converter clutch error (E400)
65 r ~ Overdrive Cancel Switch (OCS) not changing state (E40D)
66 oc ~ TOT indicated 290F/circuit grounded (E40D)
67 oc ~ Manual Lever Position (MLP) sensor out of range; A/C on (E40D)
67 0 ~ Neutral Drive Switch (NOS) circuit open; AIC ON (ManuaI/C6)
(Continued)

ALL RIGHTS RESERVED
-
7.5L
EFI
74 r ~ Brake On/Off (BOO) circuit open - not actuated during Self-Test
77 r ~ Operator error Dynamic Response Test
93 0 ~ Coast Clutch Solenoid (CCS) circuit failure (E40D)
94 0 ~ Converter Clutch Control (CCC) solenoid circuit failure (E40D)
95 oc ~ Fuel pump circuit open ECA to motor ground
96 oc ~ Fuel pump circuit open battery to ECA
97 0 ~ Overdrive Cancel Indicator Light (OCll) circuit failure (E40D)
98 0 ~ Electronic Pressure Control (EPC) driver failure in Processor (E40D)
99 oc ~ Electronic Pressure Control (EPC) circuit failure (E40D)

ALL RIGHTS RESERVED
SECTION 17
..
EEC-IV Pinpoint Test Procedures
Contents
Pinpoint Test Index 17-1

ALL RIGHTS RESERVED
EEC-IV Pinpoint Test Procedures 17-1
Pinpoint Test Index
PINPOINT TEST PAGE

LETTER PINPOINT TEST TITLE NUMBER
A EEC-IV No Start 17-2
AA : EEC-IV No Start (EDIS) , 17-11
B Vehicle Battery 17-17
C Reference Voltage : 17-23
SENSOR INPUTS
DA Temperature Sensor Test ACT, ECT and VAT 17-29
DC : Mass Air Flow (MAF) Sensor 17-40
DD EGR V~lve Position Sensor (EVP) Control/Vent (EGRC/EGRV) 17-48
DF Manifold Absolute Pressure (MAP)/Barometric
Pressure (BP) Sensor ' 17-60
DG Knock. Sensor ' ~ ~ ~ : 17-72
DH Throttle Position (TP) Sensor 17-76
DJ Engine RPM Sensor (Diesel) 17-91
DK Vane Air Flow (VAF) Sensor 17-94
Dl Pressure Feedback EGR (PFE) EGR Vacuum Regulator (EVR) 17-107
DN EGR Valve Posi,tion (EVP) Sensor EGR Vacuum Regulator (EVR)
Solenoid 17-125
DP Vehicle Speed Sensor (VSS) 17-142
DO Fuel Injection Pump lever (FIPl) Sensor 17-149
DR Cylinder Identification (CID) Sensor 17-161
ADDITIONAL INPUTS
FA Neutral Drive Switch A/C Input 17-165
FD Brake On/Off (BOO) 17-179
FF Power Steering Pressure Switch (PSPS) 17-191
FUEL CONTROL SYSTEMS
H Fuel Control .! 17-197
J Fuel Pump Circuit 17-228
PROCESSOR OUTPUTS
KA EGR On/Off Control , 17-246
KB DC Motor Idle Speed Control/ldle Tracking Switch and Throttle
Position Sensor - 1.9l CFI and 2.5l CFI 17-250
KC Air Management System (AM1/AM2) 17-267
KD Canister Purge (CANP) ~... 17-274
KE .Idle Speed Control (Bypass Air) 17-280
KF Electro Drive Fan (EDF)/High Electro Drive Fan (HEDF) 17-290
KH Service Pin Adjustment :.......................................... 17-303
Kl Shift Indicator Light (Sll) 17-306
KM WOT A/C Cutout (WAC) A/C Demand : 17-312
KP Octane Adjust 17-328
KT :Intake Air Control Valve (lAC) System ; 17-330
M Dynamic Response Test 17-335
Ml "CHECK ENGINE" or "SERVICE ENGINE SOON" Light/Message
"CHECK ENGINE" I"CHECK DCl" Message 17-337
N ; Ignition/Erratic Diagnostic Monitor (IDM) : 17-346
P Spark Timing Check :............................................................... 17-365
OA No Codes/Codes Not Listed 17-374
OB Key On Engine Off and/or Continuous Memory Service Code 15........... 17-379
OC Output State Check Not Functioning 17-382
OD Re-Initialization Check 17-384
OE Key Power Check 17-388
S System Check 17-391
T Transmission - AXOD 17-397
TB Transmission - A4lD ;.:........................................................... 17-414
Te, Transmission - E40D : 17-418
X .Integrated Controller, ' '... .. 17-445

ALL RIGHTS RESERVED
17-2 EEC-IV Pinpoint Test Procedures
IEEe-IV
No Start
Pinpoint
Test
A
INote I
You should enter this Pinpoint Test only when Quick Test has been successfully
completed and the engine is still a no start or when directed here from Section 13.
IRemember I
To prevent the replacement of good components, be aware that the following non-EEC areas
may be at fault:
Fuel: quantity and quality TFI or DIS module

Ignition: general condition, moisture, Distributor
cracks, damage, etc.
Camshaft sensor (CID)
Engine: internal, valves, timing belt,
camshaft Single hall crankshaft sensor (PIP)
Starter and battery circuit Ignition coil or DIS coil
Dual hall sensor
This Pinpoint Test is intended to diagnose only the following:

Spark (as related to EEC-IV)
Harness circuits: PIP, SPOUT, IGN GND, VPWR

Processor assembly (-12A650-)
NOTE: This pinpoint test is intended to diagnose TFI ignition systems, Closed Bowl
Distributor (CBD) with remote mount TFI systems and Distributorless Ignition
Systems (DIS).
. To identify your system, please refer to the application chart below.
IGNITION SYSTEM APPLICATION CHART:
Ignition Connector Vehicle Application

DIS Connector (Pins 1-6 and 7-12) 2.3L EFI Truck, 3.0L SHO, 3.8L SC
D.istributor Hall' Connector and TFI Connector
(used for closed bowl distributor, remote mount 3.8L AWD, 3.8L AXOD, 7.5L Truck
TFI systems)
TFI Connector All Others

ALL RIGHTS RESERVED
IEEe-Iv Pinpoint
A
No Start Test
IPinpoint Test Schematic I

APPLICATIONS: 3.8L SEFI AXOD. 3.8L SEFI RWD, 7.5L EFI TRK
DISTRIBUTOR HALL VEHICLE
HARNESS CONNECTOR
* TEST PIN 16 0~--------
TEST PIN 56 0~--------PIP----01

IN-LINE
SPOUT CONNECTOR
TESTPIN36 0~--------SPOUT--------I~-+------+...a
TFI MODULE VEHICLE

HARNESS CONNECTOR
*TEST PINS LOCATED ON BREAKOUT BOX.
ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. 'A9203-B
TFI Module Location Test Pin 36 Spout

Application Location Application Wire Color
3.8L SEFI AXOD' Cowl 7.5L TRK F-Series PK
3.8L SEFI RWD Radiator Support All Others Y/LG
7.5L EFI TRK Distributor
Test Pin 56 PIP
Test Pin 16 IGN. GND Application Color
Application Wire Color 7.5L TRK F-Series GY/O
3.8L SEFI AXOD " GY All Others OS
3.8L SEFI RWD
SK/O
7.5L EFI TRK E-SERIES
7.5L EFI TRK F-SERIES
-0
"

ALL RIGHTS RESERVED
IEEe-IV
No Start
Pinpoint
Test
A

ALL OTHER TFI APPLICATIONS
*TEST PIN 56G) PIP ~u

IN-LINE SPOUT
TEST PIN 36G) SPOUT
CONNECTOR r HJ
0 ~
0
0 [l
TEST PIN 160 IGN GND r-t-iJ
TEST PIN 40 AND 60 <;)
TEST PIN 37 AND 57 G)

BKlLG
R
PWR GND
VPWR
T
TFI MODULE
VEHICLE HARNESS
CONNECTOR

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE.
NOTE: WHEN BREAKOUT BOX IS INSTALLED, ENSURE THAT TIMING SWITCH IS IN
"COMPUTED" POSITION UNLESS OTHERWISE NOTED.
A9576-D
Test Pin 56 PIP Test Pin 36 SPOUT

Application Wire Color Application Wire Color
5.8L F-Series/Bronco 4.9L F-Series/Bronco
GY/O
5.0L F-Series/Bronco 5.0L F-Series/Bronco PK
5.8L F-Series/Bronco
3.0L Probe BK
3.0L Probe R
2.9L Scorpio BL/Y
2.9L Scorpio BLIR
All Others DB
5.0L Lincoln Town Car GY/O
All Others Y/LG
Test Pin 16 IGN GND_

Application Wire Color
5.0L F-Series/Bronco 0
3.0L Probe W
2.9L Scorpio BR
All Others BK/O

ALL RIGHTS RESERVED
EECIV Pinpoint Test Procedures 17-5
IEEe-Iv Pinpoint
A
No Start Test

2.3 OHC EFI Truck
VBAT: KEY POWER r----------.:D::..:P....:.I..:...:(32..::.):.....-- -;ini'ii'7A'\l5I"il~rA!""o_____TG7.!Y~/07_0.32 TEST PIN'

BOTH START & RUN
______________ PIP (~) - - - - - - - - DB 4 TEST PIN
DUAL HALL
SENSOR S U (36)-----....rr'-----.....;..--;,,--.;:;Y;.;;:/L-=G-Co) 56 TEST PIN
(SPK TIMING/CIO) IGN GND (J) BKIO' 36 TEST PIN
_ _ __ _ .... J 16 TEST PIN
CID I IGNGNO
L CASE GND--{?> 20 TEST PIN
DIS IGNITION
3 - o o MODULE PINS
VBAT-~
712
::: _. , ,.........,PW'II .... I I COIL 1
SHELD
r l
I I
I
DIS
MODULE
(FRONT VIEW)
CONNECTOR : :
I I
I I
I~
I I
I I
~ I
I I
I I
I: SECONDARY DIS PRIMARY DIS
I I SPOUT DISCONNECT LOCATED COILS COILS
: L __ ----- I I ADJACENTlOTHE 1-6 PIN DIS. LEFT SIDE RIGHT
________c..:_-_-_-__ ----------------..J-..:.:.MOD=..;;;,U~LE~C~ON;;.;.;.;.N.;.;...----- ..:..O;...F..:..EN...;..G::..:I.;.:.N..::.E_~..._-:V..::B::..:AT..;.",..-...J ~~JI~~
A9205A
3.0L ~HO SEFI MA and 3.8L SEFI SC
CRANKSHAFT
SENSOR
(3.0l) SINGLE HALL ..-------,~r=-==-=:.=.:=:.=..:=-=-=-=:..=..=-==-=.=....:;.=~:E:._----~~-<_).
56 TEST PIN'
CRANKSHAFT 024 TEST PIN
SENSOR 36 TEST PIN
P'ip:~~DIS ~rvT gJ ~~~i~ "NIT""COIL

POWER (3.8L)
START
AND
VBAl IGN GND RUN
CRANKSHAFT
SENSOR
(3.8L)
1 12
POU 5
:0
2
DIS
MODULE
(lOP VIEW)
0
11
10
9
8
IN-LINE 6 7
SPOUT
DIS MODULE CONNECTOR
PINS 1-6 PINS 7-12
'TEST PINS LOCATED ON BREAKOUT BOX. ALL HARNESS CONNECTORS VIEWED INlO
A13537-A
MATING SURFACE.
Test Pin 4 10M Test Pin 16 IGN. GNO

13.OL SHO MA GY/O 13.OL SHO MA SK/O
3.8L SC MA DG/Y 3.8L SC MA LS

ALL RIGHTS RESERVED
176 EECIV Pinpoint Test Procedures
IEEe-Iv Pinpoint
A
No Start Test
I WARNING I
STOP THIS TEST AT THE FIRST SIGN OF A FUEL LEAK AND SERVICE AS REQUIRED.
f CAUTION:I
No open flame - No smoking during fuel delivery checks.
A1 I ATTEMPT TO CRANK ENGINE
NOTE: For DIS vehicles, If continuous memory Yes ~ GO to IA21.

code 19 is present, go to Pinpoint Test
Step [Jill. No ~ REFER to Starting/
Does engine crank? Engine Shop Manual
Group.
A2 I CHECK FOR VREF AT THROTTLE POSITION

SENSOR
NOTE: Verify fuel pump inertia switch Is set Yes RECONNECT TP

(button pushed in). Refer to Owner's sensor. GO to IA31.
Guide for location.
Key off, wait 10 seconds.
No
GO to Pinpoint Test
Step IC11.
Disconnect TP sensor.
Key on, engine off.
Measure voltage between VREF circuit and SIG
RTN circuit at the TP sensor vehicle harness
connector.
Is voltage between 4.0 volts and 6.0 volts?
SIGRTN ~
TP SI~~~~-------~
ALTERNATE THROTTLE POSITION
SENSOR VEHICLE HARNESS CONNECTOR
SIG RTN
~
~~
TP--------+I4~ ~
VREF ~~.1
po
:: ~
THROTTLE POSITION (TP) c:J

A13613-A

ALL RIGHTS RESERVED
EECIV Pinpoint Test Procedures 177
IEEe-Iv Pinpoint
A
No Start Test
A3 I CHECK FOR SPARK AT PLUG'S
Disconnect the spark plug wire to any accessible Yes ~ GO to IA121.

cylinder (on 2.3L DIS truck, disconnect exhaust
side spark plug only.) No ~ For DIS vehicles:
Connect spark tester between spark plug wire and GO to IASI.
engine ground.
For all others:
Crank engine and check for spark. GO to IA41.
Reconnect the spark plug wire to the spark plug.
Was spark present and consistent?
.
A4 I'CHECK FOR SPARK AT COIL
Remove high tension coil wire from' distributor and Yes ~ ,REFER to Section 13,
install spark tester. Part 2 for TFI cap,
,rotor and wires
Check for spark while cranking.
diagnosis.
Reconnect high tension coil wire to distributor.
Was spark present during crank? No ~ GO to IASI.
,
AS I CHECK CONTINUITY OF GND CIRCUIT
I
Key off, wait 10 seconds. Yes ~ GO to IA61.

Disconnect processor 60 pin connector. Inspect
for damaged or pushed out pins, corrosion, loose No ~ SERVICE open circuit.
wires, etc. Service as necessary. REMOVE breakout box.
Install breakout box, leave processor disconnected. RECONNECT all
components. RERUN
DVOM on 200 ohm scale. Quick Test.
Disconnect TFI module or DIS module (pins 7-12).
(For 3.8L AXOD, 3.8L RWD and 7.5L truck,
disconnect distributor hall connector.)
Measure resistance between Test Pin 16 at the
breakout box and TFI, distributor hall or DIS
vehicle harness connector IGN GND circuit.
Is resistance less than s.o ohms?
A6 I ISOLATION OF PROBLEM TO SPOUT CIRCUIT
Reconnect TFI module or DIS module (pins 7-12). Yes ~ Timing switch to
(For 3.8L AXOD, 3.8L RWD and 7.5L truck, "Computed" position
reconnect distributor hall connector.) on breakout box. GO
to IA101.
Breakout box installed.
Connect processor to breakout box. No ~ GO to IA71.
Timing switch to "Dist". position on breakout box.
Attempt to start vehicle.
Does the vehicle start?

ALL RIGHTS RESERVED
IEEe-IV
No Start
Pinpoint
Test
A

,
A7 I CHECK SPOUT SIGNAL
Key on, engine off. Yes ~ EEC system OK.

REMOVE breakout box.
Breakout box installed, processor connected. RECONNECT all
Timing switch to "Computed" position on breakout components. REFER to
Section 13 for TFI or
box. DIS diagnosis.
Measure voltage between Test Pin 36 at the No ~ GO to IASI.
breakout box and battery negative post during
crank.
Is voltage between 3.0 and 6.0 Yolts?
A8 ICHECK SPOUT AND PIP CIRCUITS FOR

SHORTS TO POWER AND GROUND

No ~ SERVICE short circuit.
Disconnect processor. REMOVE breakout box.
- RECONNECT all
For 3.8L SC or 3.0L SHO:
components. RERUN
- Disconnect crankshaft sensor. Quick Test. If vehicle
does not start, GO to
For 2.3L Truck: IA91.
- Disconnect DIS module (pins 1-6) connector.
For 3.8L AXOD, 3.8t RWD and 7.5L Truck:
- Disconnect distributor hall connector.
For all others:
- Disconnect TFI module.
DVOM on 200,000 ohm scale.
Measure resistance between Test Pin 36 (SPOUn
and Test Pins 16, 20, 40, 46, 60 (short to
GROUND), 26, 37, 57 (short to POWER) and 56
(short to PIP) at the breakout box.
Measure resistance between Test Pin 56 (PIP)
and Test Pins 16, 20, 40, 46, 60 (short to
GROUND), 26, 37, 57 (short to POWER).
Is each resistance greater than 10,000 ohms?

ALL RIGHTS RESERVED
IEEe-Iv Pinpoint
A
No Start Test
A9 I ISOLATE SHORT(S) IN PROCESSOR
Key off, wait 10 seconds. Yes ~ RECONNECT all

Breakout box installed. IcomQonents. GO to
A10 .
Reconnect processor to breakout box.
TFI module or DIS module (Pins 1-6)
disconnected. (For 3.8L AXOD, 3.8L RWD and No ~ REPLACE processor.
7.5L truck TFI, distributor hall connector REMOVE breakout box.
disconnected.) RECONNECT all
components. RERUN
DVOM on 200,000 ohm scale. Quick Test.
Measure resistance between Test Pin 36 (SPOUn
and Test Pins 37 and 57 (short to POWER) also,
Test Pins 40 and 60 (short to GROUND) at the
breakout box.
Measure resistance between Test Pin 56 (PIP)
and Test Pins 37 and 57 (short to POWER). Also
Test Pins 40 and 60 (short to GROUND) at the
breakout box.
Is each resistance greater than 500 ohms?
A 10 I CHECK PIP SIGNAL

Breakout box installed, processor connected. REMOVE breakout box.
RECONNECT all

DVOM to 20 volt scale.
Measure voltage between Test Pin 56 and Test . components. RERUN
Quick Test.
Pin 16 at the breakout box. (For 2.3L DIS truck,
switch timing switch to "Dist" position on
breakout box.) No ~ GO to IA111 (for 2.3L
DIS truck, switch timing
Crank engine, record reading. switch to "Computed"
Is Yoltage between 3.0 and 7.0 Yolts? position on breakout
box.)
A11 I CHECK CONTINUITY OF PIP CIRCUIT
Key off, wait 10 seconds. Yes ~ REMOVE breakout box.

Breakout box iflstalled. RECONNECT all
components. REFER to
Disconnect processor. Section 13 for TFI or
For 3.8L SC or 3.0L SHO: DIS diagnosis.
- Disconnect crankshaft sensor.
For 2.3L Truck: No ~ SERVICE open circuit.
- Disconnect DIS module (pins 1-6) connector. REMOVE breakout box.
For 3.8L AXOD, 3.8L RWD and 7.5L Truck: RECONNECT all
- Disconnect distributor hall connector. components. RERUN
Quick Test.
For all others:
- Disconnect TFI module.
breakout box and PIP circuit at the following
connectors as appropriate: TFI, distributor hall, PIP
sensor, or 2.3L TK DIS PIP circuit.
Is resistance less than 5.0 ohms?

ALL RIGHTS RESERVED
1710 EEC-IV Pinpoint Test Procedures
IEEe-IV Pinpoint
A
No Start Test
A12 I SPOUT SIGNAL VERIFICATION

for damaged or pushed out pins, corrosion, loose No ~ GO to IASI.
Install breakout box and connect processor to
breakout box.
Ensure timing switch is in "Computed" position on
breakout box.
Measure voltage between Test Pin 36 and Test
Pins 40 and 60 at the breakout box during crank.
Is Yoltage between 3.0 and 6.0 Yolts? -.
A20 I CHECK FUEL PRESSURE
I WARNING I Yes ~ For all EFI and SEFI:

GO to Pinpoint Test
Step IS11.
IF FUEL STARTS LEAKING, TURN KEY OFF
IMMEDIATELY. NO SMOKING. For all CFI:
GO to Pinpoint Test
Connect fuel pressure gauge. Step IS21.
Note initial pressure reading.
Observe pressure gauge as you pressurize fuel No ~ TURN rey ?FF and
system. (Turn key to RUN for 1 second, then turn GO to A21 .
key to OFF. Wait 10 seconds. Repeat 5 times.)
..
Does fuel pressure Increase?
A21 I CHECK INERTIA SWITCH RESISTANCE
Key off. Yes ~ For 2.5L HSC-CFI,

3.0L EFI and 3.8L
Disconnect fuel pump inertia switch. Refer to AXOD EFI passenger
Owner Guide for location. car:
DVOM on 200 ohm scale. GO to IX111.
Measure the resistance of the fuel pump inertia For all others:
switch. GO to QI].
No ~ VERIFY inertia switch
is reset. If switch will
_not reset, REPLACE
switch. REMOVE
breakout box.
RECONNECT all
components. R~RUN
Quick Test.

ALL RIGHTS RESERVED
IEEe-Iv Pinpoint
AA
No Start (EDIS) Test
INote I
You should enter this Pinpoint Test only when Quick Test has been successfully
completed and the engine is still a no start or when directed here from Section 13.
IRemember I
To prevent the replacement of good components, be aware' that the following non-EEC areas
may be at fault:
Fuel: quantity and quality EDIS module

Ignition: general condition, moisture, Distributor
cracks, damage, etc. Single hall crankshaft sensor (PIP)
Engine: internal, valves, timing belt,
camshaft Coil Packs
Starter and battery circuit
Variable. Reluctance sensor (VRS)

Spark (as related to EEC-IV)
Harness circuits: PIP, IGN GND, VPWR

ALL RIGHTS RESERVED
IEEe-IV .
No Start (EDIS)
Pinpoint
Test
AA
1.9L MA SEFI (EDIS)
VARIABLE RELUCTANCE SENSOR (VRS)

VEHICLE HARNESS CONNECTOR
140-- VRS ( + )
VRS (-) (GR)
(BL)
TEST PIN 37 e-,

TEST PIN 57 ~W/R--VPWR---t~ ......""'1
I
TEST PIN 16 0-- R/BL-IGN GND 1\

-Q ,I TO IGNITION
,
I \ I START/RUN
TEST PIN 36 0--LG/W.SAW(J)O'

J
I
I RIY
J
I
t
t!J
\ I COIL 1 _ GRN + i J j L
TEST PIN 56 0-- GR/W - PIP
COIL 2 - BRIA
TEST PIN 4 c:>--- R-IDM ----+-... IGNITION COIL

VEHICLE HARNESS
CONNECTOR
&==*~t::1:=t:~~::::t=~~=" BKiGA ~
BATTERY
(J) SAW IN-LINE CONNECTOR NEGATIVE
POST
EDIS MODULE
"TEST PINS LOCATED ON BREAKOUT BOX.
A13559-A

ALL RIGHTS RESERVED
IEEe-Iv Pinpoint
AA
4.0L MA EFI Truck (EDIS)
VARIABLE ,RELUCTANCE SEN~OR (VRS)

VRS (-)
~----. + VBAT
+ VBAT
"T.EST PIN 16 e--t-t-- - -
IGN GND - BKIO
----I
1
PIN 4
\ . I
TEST PIN 36 <:>:0 I SAW -Y/LG ~
. , I PIN 3
\ I I COIL 2 ---+--+++H'HTl
TEST PIN 56 0 \.} PIP I ~- COIL 3--+-+++4~
- -- -, II
......00+-- COIL 1 PIN 2
I... I
TEST PIN 4 (5)-IDM-DGIY I
I PIN 1
I
IGNITION COIL
'VEHICLE HARNESS
t-~ ,.....+........+----~...,
CONNECTOR
BATTERY
NEGATIVE
POST
EDIS MODULE
ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A13560A
Test Pin 56 PIP

4.0L Aerostar DB
4.0L Ranger/Bronco II BK/LB

ALL RIGHTS RESERVED
IEEe-IV
No Start (EDIS)
Pinpoint
Test
AA
I WARNING I
STOP THIS TEST AT THE FIRST SIGN OF A FUEL LEAK AND SERVICE AS REQUIRED.
f ~~UTIO~]
No open flame - No smoking during fuel delivery checks.
AA1 I ATIEMPT TO CRANK ENGINE
NOTE: Verify fuel pump inertia switch is set Yes ~ GO to IAA2/.

(button pushed In). Refer to Owner's
Guide for location. No ~ REFER to Startin~/
Does engine crank? Engine Group in hop
Manual.
AA21 CHECK FOR VREF AT THROTTLE POSITION -

SENSOR
Key off, wait 10 seconds. Yes ~ RECONNECT TP

DVOM on 20 volt scale. sensor. GO to IAA31 .
Key on, engine off. No ~ GO to Pinpoint Test
Measure voltage between VREF circuit and SIG Step IC11.
connector.
Is voltage between 4.0 volts and 6.0 volts?
..bid..
SIG. RTN. L..
~-
~~
THROTTLE
POSITION (TP)
TP loft- SENSOR VEHICLE
ru HARNESS
VREF ~r ~ CONNECTOR
~
A 11502-e
AA3 I CHECK FOR SPARK AT PLUGS
Disconnect the spark plug wire to any accessible Yes ~ GO to IAA41.

cylinder.
Connect spark tester between spark plug wire and No ~ REFER to Section 13
engine ground. for EDIS diagnosis.
Crank engine and check for spark.
Reconnect the spark plug wire to the spark plug.
Was spark present and consistent?

ALL RIGHTS RESERVED
IEEe-Iv . Pi~point
AA
AA41 CHECK CONTINUITY OF IGNITION GROUND

. CIRCUIT
Key off, wait fo seconds. Yes ~ GO to IAASI.

components. RERUN
Disconnect EDIS module.
breakout box and IGN GND circuit at the EDIS
module vehicle harness connector.
Is resistance . less than 5.0 ohms?
AA51 CHECK PIP CIRCUIT FOR SHORTS TO POWER

AND GROUND
Key off, .wait 10 seconds. .. Yes ~ GO to IAA61 ..

Breakout box installed, processor disconnected.
EDIS module disconnected. No ~ SERVICE short circuit.
DVOM on 200,000 ohm scale. RECONNECT all
Measure resistance between Test Pin 56 (PIP) components. RERUN
and Test Pins 16, 40, 46, 60 (short to GROUND), Quick Test, if vehicle
26, 37, 57 (short to POWER). does not start. GO to
Is each resistance greater than 10,000. ohms? IAA61.
AA6 I ISOLATE SHORT(S) IN PROCESSOR
Key off, wait 10 seconds. Yes ~ RECONNECT all

Breakout box installed. Fom3onents. GO to
AA7. .
EDIS module disconnected. No ~ REPLACE processor.
DVOM on 200,000 ohm scale. REMOVE breakout box.
Measure resistance between Test Pin 56 (PIP) RECONNECT all
and Test Pins 37, 57 (short to POWER),. 40, and components. RERUN
60 (short to GROUND) at the breakout box. -. Quick Test.
AA7 I CHECK PIP SIGNAL
Key off. Yes ~ GO to IAA91.

Breakout box installed, processor connected.
DVOM to 20 volt scale. No ~ GO to IAASI.
Pin 16 at the breakout box.
Crank engine, record reading.
Is Yoltage between 3.0 and 7.0 YOIts? .

ALL RIGHTS RESERVED
IEEe-IV
No Start (EDIS)
Pinpoint
Test
AA
AA8 I CHECK PIP CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes ~ If Continuous Memory

Code 14 is present:
Breakout box installed. GO to Section 13 for
Disconnect processor. EDIS diagnosis.
Disconnect EDIS module. If no Continuous

Memory Code 14 is
DVOM on 200 ohm scale. present: .
Measure resistance between Test Pin 56 at the GO to IAA91.
breakout box and PIP circuit at the EDIS module
vehicle harness connector. No ~ SERVICE open circuit.
Is resistance less than 5.0 ohms? RECONNECT all
components. RERUN
Quick Test.
AA9 I CHECK FUEL PUMP
No smoking nearby. Yes ~ GO to Pinpoint Test

Step ~.
Connect fuel pressure gauge.
Note intial pressure reading. No ~ GO to Fuel Group in
Shop Manual to check
Observe pressure gauge as you pressurize fuel for mechanical
system. (Turn key to RUN for 1 second, then turn problems in fuel
key to OFF. Wait 10 seconds. Repeat 5 times.) system.
Does fuel pressure increase?
I WARNING I
IF FUEL STARTS LEAKING, TURN KEY OFF
IMMEDIATELY. NO SMOKING.
'"

ALL RIGHTS RESERVED
Pinpoint
IVehicle Battery Test
B
INote I
You should enter this Pinpoint Test only when directed here from Pinpoint Tests ~ ,
QJ or ~. .
IRemember I
may be at fault:
Ignition Switch
Battery Cables
Alternator
Voltage Regulator
Ground Straps
Processor (-12A650-)
Harness circuits: SIG RTN, STO, STI, PWR GND, GROUND, VPWR, KAPWR, VREF,
IGNITION
Battery Voltage
Power Relay (-12A646-)
5.0L SEFI Lincoln Town Car, Crown Victoria/Grand Marquis

5.0L SEFI MA Lincoln Town Car, Crown Victoria/Grand Marquis
"TEST PIN 370--- R VPWR------..,
TEST PIN 57 0-- R VPWR-----_
TEST PIN 40 0---J TO IGNITION
SWITCH
TEST PIN 60 ~BKlLG -PWR GND START/RUN
TO BATIERY GND~---
RELAY BLOCK VEHICLE HARNESS CONNECTOR

(LOCATED ON VACUUM RESERVOIR) A 13606-A

ALL RIGHTS RESERVED
Pinpoint
B

*TEST PIN 46 0-- BKIW _ _ RTN ~--..., SELF-TEST
CJ CJ CONNECTOR PIGTAIL
1 CJ CJ
~c:J TCOONNECTOR
TEST PIN 17 0-""'"- STO _ ......... CJ CJI
SELF-TEST
TEST PIN 48 0 STI INPUT
TO BAIT
TEST PIN 40 &BKlLG--PWR GND--------r---"""'lIi~
GND PIGTAIL
d!!:\\
TEST PIN 60 0-BKlLG - - PWR GND - - - - - - _ _ .
TEST PIN 50-KEY POWER

IGNITION ---;:=n;::;c EEC POWER
TO IGNITION ~R/LG~";""------~ RELAY VEHICLE
SWITCH HARNESS CONNECTOR
TEST PIN 37 0 - R - V P W R - - - -__
TEST PIN 57 ~R-VPWR----~ ---~ TO BAITERY
TEST PIN 1 0 K A P W R - - - - - - - - - - 4 . - - -...- - - - t

TEST PIN 20 0 - B K - G R O U N D - - - - - - - - l TO CHASSIS FUSE TO
GROUND LINK STARTER
TEST PIN 26 0-01W-
VREF -= )
TO SENSORS MOTOR
RELAY
TEST PIN 49 0 - 0 - EGO GND C)
ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A9577-E

ALL RIGHTS RESERVED
Pinpoint
B
Test Pin 17 STO Test Pin 1 KAPWR

Car: 2.9L Scorpio BK/BL
1.9L EFI T/LB 1.9L MA SEFI BLIA
1.9L MA SEFI 3.0L Probe
3.8L RWD-SEFI Car:
Y/BK
3.8L SEFI-SC
5.0L SEFI, Mark VII ,
2.3L OHC MA -
2.3L OHC, .EFI
2.9L Scorpio BRIG 5.0L SEFI, Mark VII BK/O
5.0L SEFI-MA Mustang
3.0L Probe W/BL
Truck: "
2.3L OHC EFI
E-Series
5.0L MA T \
Truck:
Truck:
2.3L EFI
F-Series PK/LG
2.3L MA EFI ,.
Y/BK
All Others T/A 2.9L EFI :
2.9L MA EFI
Car:
5.0L MA SEFI Town Car
All Others Y
Test Pin 48 STI

Application Wire' Color
1.9L MA SEFI LG/Y
2.9L Scorpio BLIG
'.
Car:
2.5L CFI CLC
2.5L CFI MTX
3.0L EFI W/BK
3.8L SEFI MA
5.0L MA SEFI, Crown
Victoria/Grand Marquis
5.0L MA SEFI Mustang TIA
F-Series W/P
All Others W/A

ALL RIGHTS RESERVED
Pinpoint
8
81 I CHECK BAITERY VOLTAGE
Key on, engine off. Yes GO to 1821.

No SERVICE discharged
Measure voltage across battery terminals. battery. REFER to
Charging/ Electrical
Is Yoltage greater than 10.5 Yolts? Group in Shop Manual.
82 I CHECK PWR GND CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes GO to IB31.

for damaged or pushed out pins, corrosion, loose No ~ . SERVICE open in PWR
wires, etc. Service as necessary. GND circuit. REMOVE
breakout box.
Install breakout box and connect processor to RECONNECT
breakout box. . processor. RERUN
Quick Test.
Measure resistance between battery negative post
and Test Pins 40 and 60 at the breakout box.
83 ICHECK FOR OPEN BETWEEN SIG RTN AND

PWR GND CIRCUITS AT PROCESSOR
Key off, wait 10 seconds. Yes GO to 1841.

No REPLACE processor.
DVOM on 200 ohm scale. REMOVE breakout box.
Measure resistance between Test Pm 46 and Test RERUN Quick Test.
Pins 40 and 60 at the breakout box.

ALL RIGHTS RESERVED
IVehicle Battery Pinpoint

Test
8
84 I CHECK SIG RTN CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes

, ~ REMOVE' breakout box.
RECONNECT CT
Breakout box installed, processor connected. processor. GO to I851 .
No ~ SERVICE open in SIG
RTN circuit. REMOVE
breakout box and SIG RTN circuit in the Self-Test breakout box.
connector. RECONNECT
Is resistance less than 5.0 ohms? processor. RERUN
Quick Test.
85 ICHECK KAPWR CIRCUIT VOLTAGE AT EEC

POWER RELAY
Key on, engine off. Yes ~ GO to IS61.

No .~ SERVICE open in
Measure ~oltage between KAPWR circuit at the KAPWR circuit between
EEC power relay vehicle harness connector and EEC power relay and
battery negative post. battery positive post.
RERUN Quick Test.
86 I
CHECK IGNITION CIRCUIT VOLTAGE AT EEC
POWER RELAY
-
Key on, engine off. Yes ~ GO to 1871.

No ~ SERVICE open in
Measure voltage between the battery negative ignition switch circuits.
post and IGNITION circuit at the EEC power relay RERUN Quick Test.
vehicle harness connector.
Is v~ltage greater than 10.5 volts?

ALL RIGHTS RESERVED
1722 EEe-IV Pinpoint Test Procedures
Pinpoint
B
87 I CHECK PWR GND CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes ~ GO to IBSI.

,
Measure resistance between PWR GND circuit at
RERUN Quick Test.
the EEC power relay vehicle harness connector
and battery negative post.
88 ICHECK VPWR CIRCUIT VOLTAGE

AT EEC POWER RELAY
Key on, engine off. Yes ~ SERVICE open or short

to ground in VPWR
DVOM on 20 volt scale. circuit between
Measure voltage between battery negative post processor and EEC
and VPWR circuit at the EEC power relay vehicle power relay. RERUN
harness connector. Quick Test.
Is the voltage greater than 10.5 volts? No ~ REPLACE EEC power

relay. RERUN Quick
Test.

ALL RIGHTS RESERVED
IReference Voltage Pinpoint

Test
c
INote I
You should enter this Pinpoint Test only when a check for VREF has failed in the
sensor Pinpoint Tests (O-Series) or Pinpoint Tests [!] or IQA I.
IRemember I
Pro'cessor assembly (-12A650-)
Sensor harness circuits: SIG RTN, VREF

TO SENSORS (ALSO 4EAT MODULE
>E=BJ
All Except 2.9L EFI Car
!
-->~ FOR 1.9L MA SEFI AfT AND
3.0L PROBE AfT)
*TESTPIN26 G) VREF------
APPROPRIATE G) SENSOR SIGNAL '\
TEST PIN 7
3-WIRE
TEST PJN 46 0 SIG R T N - A - - - - - -....- -....... SENSOR
FROM
SENSORS
SELF-TEST
TEST PINS LOCATED ON BREAKOUT BOX. CONNECTOR
ALL HARNESS CONNECTORS VIEWED INTO' MATING SURFACE. A9578-E
2.9L EFI Car

TEST PIN 26 0--BR/BK
APPROPRIATE TEST PIN 0------SENSOR SIGNAL
VREF--~~
r-=-= TO SENSORS
)
)
SEJ .
TEST PIN 46 0-- SR SIG RTN t )

FROM SENSORS
3-WIRE
SENSOR
TEST PIN 40 ~BR"":'PWR GND
rEST PIN 60 ~ . CJ CJ CJ CJ
SELF-TEST
*TEST PINS LOCATED ON BREAKOUT BOX. CONNECTOR
A13610-A

ALL RIGHTS RESERVED
17-24 EEe-IV Pinpoint Test Procedures

Test
c
Test Pin 26 VREF

1.9L MA SEFI R/W
F-SerieslBronco BR/W
3.0L Probe LG/R
All Others O/W
Test Pin 46 SIG RTN

1.9L MA SEFI LG/BK
F-Series/Bronco GY/R~
3.0L Probe LG/Y

All Others BK/W

ALL RIGHTS RESERVED
EEe-IV Pinpoint Test Procedures 1725

Test
c
C1 I CHECK VEHICLE BATIERY POWER CIRCUIT
Key off. wait 10 seconds. Yes ~ GO to IC21.

Disconnect 60 pin connector. Inspect for damaged
or pushed out pins. corrosion. loose wires. etc. No ~ RECONNECT sensor (if
Service as necessary. applicable).
Install breakout box and connect processor to For 2.5L HSC CFI,
breakout box. 3.0L EFI car, 3.0L
SHO, 3.8L AXOD and
DVOM on 20 volt scale. 3.8L SIC:
Key on. engine off. . GO to [X1J.
Measure voltage between Test Pin 37 at the For all others:
breakout box and SIG RTN/PWR GND circuit in GO to OOJ.
the Self-Test connector.
Is Yoltage greater than 10.5 Yolts?
C2 I CHECK VREF VOLTAGE
Key on. engine off. Greater than .~ GO to IC41.

6.0 volts
Breakout box installed. processor connected.
DVOM on 20 volt scale. Less than 4.0 ~ GO to Icsl.
Measure voltage between Test Pin 26 and Test volts
What is the Yoltage?
Between 4.0 ~ GO to Ical.
volts and 6.0
volts
C3 ICHECK VREF AND SIG RTN CIRCUITS

FOR CONTINUITY .
Key off. Yes ~ Reference voltage OK.

Sensor that sent you here disconnected. RECONNECT sensor.
Breakout box installed. RERUN Quick Test.
Disconnect processor.
DVOM on 200 ohm scale. VREF or SIG RTN
circuits. REMOVE
Measure resistance between Test Pin 26 at breakout box.
breakout box and VREF circuit at vehicle harness RECONNECT all
connector of the sensor that sent you here. components. RERUN
Measure resistance between Test Pin 46 at Quick Test.
breakout box and SIG RTN circuit at vehicle
harness connector of the sensor thcd sent you
here.

ALL RIGHTS RESERVED
Pinpoint
-I Reference Voltage
Test
c
C4 ICHECK FOR EXCESS VOLTAGE ON

VREF CIRCUIT
Key off, wait 10 seconds. Yes ~ REPLACE processor.

Breakout box installed. RECONNECT sensor.
Disconnect processor. RERUN Quick Test.
Disconnect Star Tester (if applicable).
NOTE: For proper results of this test, the STAR No ~ SERVICE short to
Tester must be disconnected. Due to the battery power in
circuitry of the STAR Tester and the vehicle harness.
vehicle, KPWR can be fed to the VREF REMOVE breakout box.
circuit giving the false Indication of a RECONNECT processor
short to power. and sensor. RERUN
Quick Test. If condition
Key on, engine off. persists, REPLACE
DVOM on 20 volt scale. processor.
Measure voltage between Test Pin 26 at the
breakout box and battery ground.
Is voltage less than 0.5 volts?
C5 ICHECK FOR SHORTED THROTTLE POSITION

SENSOR
Key off, wait 10 seconds. Yes ~ For vehicles equipped

Breakout box installed, processor connected. with EVPIPFE sensor:
GO to IC61.
Disconnect Throttle Position (TP) sensor from
vehicle harness. For all other vehicles:
Key on, engine off. GO to IC71.
No ~ REPLACE TP sensor.
Pin 46 at the breakout box. RECONNECT all
Is voltage less than 4.0 volts? components. RERUN
Quick Test.
C6 I CHECK FOR SHORTED EVP/PFE SENSOR
Key off, wait 10 seconds. Yes ~ GO to IC71.

TP sensor disconnected.
. Breakout box installed, processor connected. No ~ REPLACE EVP/PFE
sensor. REMOVE
Disconnect EVP/PFE sensor. breakout box.
Key on, engine off. RECONNECT all
components. RERUN
DVOM on 20 volt scale. Quick Test.
pin 46 at the breakout box.

ALL RIGHTS RESERVED
Pinpoint
IReference Voltage Test
c
.
C7 ICHECK FOR SHORTED MAP/BP
SENSOR
NOTE: For vehicle nO~ipped with a MAP/BP Yes ~ .For 1.9L EFI:
sensor, go to C10 except. 1.9L MA SEFI GO to Ical.
AIT, go to ~.
For 3.0L Probe A/T:
Key off, wait 10 seconds. GO to IC91.
~VP/PFE sensor disconnected, if so equipped. For all other vehicles:
GO to IC101.
Disconnect MAPIBP sensor. No ~ REPLACE MAPIBP
Key on, engine off: sensor. REMOVE
breakout box.
DVOM on 20 volt scale. RECONNECT processor
Measure voltage between Test Pin 26 and Test and sensor(s). RERUN
Pin 46 at the breakout box. Quick Test.
CB ICHECK FOR SHORTED VANE AIR FLOW

(VAF) SENSOR
Key off, wait 10 seconds. Yes ~ GO to IC101.

MAP/BP sensor and TP sensor disconnected.
EVP/PFE sensor disconnected, if sp equipped. No ~ REPLACE VAF sensor.
Breakout box installed, processor connected. RECONNECT all
Disconnect Vane Air Flow (VAF) sensor. components. RERUN
; Quick Test.
Key on, engine off.
Is voltage less than 4~0 volts?
C9 I CHECK FOR SHORTED 4EAT MODULE

MAP/BP, EVP/PFE disconnected, if so equipped.
No ~ REMOVE breakout box.
RECONNECT all
Breakout box installed, processor connected. components except
Disconnect both 4EAT(A/T} module vehicle 4EAT module. GO to
harness connectors. Transmission Shop
Manual Group to check
Key on, engine off. for shorted circuit in
DVOM on 20 volt scale. 4EAT system.
Pins 46 at the breakout box.

ALL RIGHTS RESERVED
17-28 EECIV Pinpoint Test Procedures
Pinpoint
IReference Voltage Test
c
C10 I CHECK FOR SHORT TO GROUND IN VREF
Key off, wait 10 seconds. Yes ~ SERVICE short to

ground. REMOVE
Breakout box installed. breakout box.
Disconnect processor. RECONNECT all
components. CONNECT
TP sensor disconnected. all sensors. RERUN
Quick Test. If original
EVP/PFE, MAP/BP, VAF sensor, and 4EAT condition still exists,
module disconnected, if so equipped. REPLACE processor.
Measure resistance between Test Pin 26 and Test No ~ REPLACE processor.
Pins 20, 40, 46 and 60 at the breakout box. RECONNECT all
Is any resistance less than 5 ohms? components. RERUN
Quick Test.

ALL RIGHTS RESERVED
Temperature Se.nsor Test Pinpoint

DA
ACT, ECT and VAT Test
INote I
You should enter this Pinpoint Test only when a Service Code 21, 24, 28, 51, 54, 58, 61,
64 or 68 is received during Quick Test. . ..
IRemember I
may be at fault:
Coolant level Engine oil level

Cooling System Thermostat
Electro drive cooling fan Heat stove duct valve operation
Water pump drive belt Air cleaner duct
Engine operating temperature Ambient temperature
This Pinpoint Test is intended to diagnose the following:
ACT sensor (-12A697-)

ECT sensor (-12A648-)
.'
VAT sensor (-12A529-)
Harness circuits: ACT, ECT, VAT and SIG RTN

ALL RIGHTS RESERVED
Temperature Sensor Test Pinpoint

DA
ACf, ECf and VAT Test
IPinpoint Test Schematics I

1.9L EFI
"TEST PIN 25 @-LG/P - - V A T - _+='~

HI-+o--VAT
TEST PIN 43 @- W/BK VAF - _+_~ Ht-t---VAF
TEST PIN 26 @- OIW VREF ----~f+__tH Ht--+-- VREF
TEST PIN 46 @- BKIW SIG RTN - ....--++""'IttJ Ht-t---SIG RTN
BLANK
VAFMETER
VANE AIR FLOW (VAF) CONNECTOR
METER VEHICLE
HARNESS CONNECTOR
ENGINE COOLANT TEMPERATURE

TEST PIN 7 0- LGN- ECT--------~oltOJlJJ~(ECT) SENSOR VEHICLE HARNESS
CONNECTOR
TEST PINS LOCATED ON BREAKOUT BOX.

ALL "HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A13538A

ALL RIGHTS RESERVED

DA
ALL EXCEPT 1.9L EFI
*TEST PIN 25 0 - - - A C T - - - - - - - - - - - - - f I I r - R ) " I AIR CHARGE TEMPERATURE (ACT)

TEST PIN 46 0 SIG RTN - - - - - ~-------I~u SENSOR VEHICLE HARNESS
CONNECTOR
ENGINE COOLANT TEMPERATURE

TEST PIN 7 0 - - - E C T - - - - - - - - - -......~ (ECT) SENSOR VEHICLE HARNESS
CONNECTOR

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A13539-A
Test Pin 7 . ECT Test Pin 46 SIG RTN

1.9L MA SEFI BL/W 1.9L MA SEFI LG/B
2.9L EFI BA/GN 2.9L Scorpio BA
3.0L Probe Y/A 3.0L EFI Probe LG/Y
7.5L, 5.8L, 5.0L 4.9L F-Series/Bronco
LG/A
F-Series/Bronco 5.0L F-Series/Bronco
5.8L F-Series/Bronco GY/R
4.9L F-Series/Bronco A
7.5L F-Series
All Others LG/Y 7.8L F-Series Diesel
All Others BK/W
Test Pin 25 ACT

Truck:
2.3L,4.9L, 5.8L,7.5L,
Y/R
5.0L E-Series
4.9L, 5.0L, 5.8L, 7.5L
GY
F-Series/Bronco
Car:
2.3L OHC, EFI/MA LG/A
2.9L EFI BA/Y
3.0L EFI Probe Y
1.9L SEFI, MA WIGA
All. Others LG/P

ALL RIGHTS RESERVED

DA
INotes: I
Engine coolant temperature must be greater than 50F to pass the KOEO test and
greater than 180F to pass the KOER test. To accomplish this, the engine should be at
normal operating temperature.
Ambient temperature should be above 50F to receive acceptable Input from the Air
Charge and Vane Air Temperature sensors.
Voltage values were calculated for VREF=5.0 volts. These values may vary 15 percent
due to sensor and VREF variations.
1---I
BROKEN LINE = VAT SENSOR
SOLID LINE = ACT & ECT

SENSORS
2v 3v 4v 5v
VOlTAGE READING (volts) A1354G-A
Engine CoolantlAir Charge Vane Air Temperature

Temperature
Temperature Sensor Values Sensor Values
OF Voltage Resistance Voltage Resistance

C (volts) (K ohms) (volts) (K ohms)
248 120 .27 1.18 0.38 0.11
230 110 .35 1.55 0.46 0.14
212 100 .46 2.07 0.56 0.19
194 90 .60 2.80 0.76 0.25
176 80 .78 3.84 0.95 0.33
158 70 1.02 5.37 1.19 0.44
140 60 1.33 7.70 1.49 0.60
122 50 1.70 10.97 1.84 0.83
104 40 2.13 16.15 2.23 1.18
86 30 2.60 24.27 2.65 1.70
68 20 3.07 37.30 3.07 2.50
50 10 3.51 58.75 3.46 3.77
Additional Data for the VAT Sensor:

r---------~--------....,
Resistance 5800 ohms
At Temperature

ALL RIGHTS RESERVED
EEe-IV Pinpoint.Test Procedures 17-33

DA
DA1 SERVICE CODE 21, 24 OR 28:

CHECK OPERATION, INSTALLATION OF
TEMPERATURE SENSOR
Service code 21 (ECT), 24 (ACT or VAn or 28 Yes ~ GO to IOA21.

(VAn indicates that the corresponding sensor is out
of Self-Test ~ange. Correct range of measure is 0.3 No ~ SERVICE other codes
to 3.7 volts. as necessary.
Possible causes:
- Low coolant level (ECT).
- Ambient temperature below 50F (ACT).
- Faulty harness connector.
-
- Faulty sensor.
Run engine for 2 minutes at 2000 rpm.
- For NO STARTS:
GO to IOA31.
- For Yehicle STALLS:
GO to IS11.
Check that upper. radiator hose is hot and
pressurized. .
Rerun Quick Test.
Are codes 21, 24, or 28 present?
DA2 CHECK VREF CIRCUIT VOLTAGE AT

THROTTLE POSITION SENSOR
Refer to schematic in Pinpoint Test IOH I. Yes ~ RECONNECT TP

sensor. GO to \OA31.
Key off, -wait 10 seconds.
Disconnect TP sensor. No ~ GO to Pinpoint Test
Step IC11.
Key on, engine off.
connector.
Is Yoltage between 4.0 Yolts and 6.0 Yolts?

ALL RIGHTS RESERVED

DA
ACT, ECT and VAT .Test
DA31 CHECK RESISTANCE OF TEMPERATURE

SENSOR WITH ENGINE OFF
NOTE: For VAT sensor, verify that the ambient Yes ~ For ACT and ECT
temperature is greater than 50F. sensors:
GO to IOA41.
Disconnect suspect temperature sensor. For ECT sensor with
a NO START:
DVOM on 200,000 ohm scale. Do not Service Code
21 at this time, GO to
Measure resistance between sensor signal circuit IA11.
and SIG RTN circuit at the temperature sensor.
Refer to the corresponding chart at the beginning For VAT sensors:
of this Pinpoint Test for resistance specifications. REPLACE processor.
RECONNECT vehicle
Is resistance within specifications? harness. RERUN Quick
Test.
No ~ For ACT sensors:

CHECK heat stove
duct valve operation. If
OK, REPLACE ACT
sensor. RECONNECT
vehicle harness.
RERUN Quick Test.
For ECT sensors:
REPLACE ECT sensor.
RECONNECT vehicle
Test.
For VAT sensors:
GO to Section 3, Vane
Air Flow Meter sensor
diagnosis.

ALL RIGHTS RESERVED

DA
DA41 CHECK RESISTANCE OF TEMPERATURE

SENSOR WITH ENGINE RUNNING
NOTE: Engine may have cooled down. Always Yes ~ REPLACE Processor.
warm engine before taking ECT sensor RECONNECT vehicle
resistance measurements. Check for open harness. RERUN Quick
thermostat. Test.
Key off. wait 10 seconds. No ~ For ACT sensors:

Suspect temperature sensor disconnected. CHECK heat stove
duct valve operation. If
DVOM on 200,000 ohm scale. OK, REPLACE ACT
Run engine for 2 f'!linutes at 2000 rpm. sensor. RECONNECT
vehicle harness.
Measure resistance between sensor signal circuit RERUN Quick Test.
and SIG RTN circuit at the temperature sensor.
Refer to the corresponding chart at the beginning For ECT sensors:
of this Pinpoint Test for resistance specifications. REPLACE ECT sensor.
RECONNECT vehicle
Is resistance within specification? harness. RERUN Quick
Test. /
I
DA10 SERVICE CODE 51, 54, OR 58:
INDUCE OPPOSITE CODE 61, 64, or 68
.
Service codes 51 (ECn, 54(ACT or VAn and Yes ~ REPLACE suspect

58(VAn indicate that the corresponding sensor sensor. REMOVE
signal is greater than the Self-Test maximum. The jumper wire.
maximum for ECT and ACT sensors is 4.6 volts. RECONNECT vehicle
The maximum for VAT sensors is 3.5 volts. harness. RERUN Quick
Test.
Possible causes:
- Temperature too low (VAn. No ~ REMov~er wire.
GO to DA11 .
- Open in harness (ACT or ECT).
- Faulty connection.
- Faulty sensor.
- Faulty processor. I
Disconnect suspect temperature sensor.
Connect a jumper wire between the sensor signal
circuit and SIG RTN circuit at the temperature
sensor vehicle harness connector.
Run Key On Engine Off Self-Test.
Is Code 61, 64 or 68 present?

ALL RIGHTS RESERVED

DA
Acr, Ecr and VAT Test
DA 111 CHECK CONTINUITY OF SENSOR SIGNAL AND

SIG RTN CIRCUITS

Suspect temperature sensor disconnected. RECONNECT all
Disconnect processor Pin 60 connector. Inspect components. RERUN
for damaged or pushed out pins, corrosion, loose Quick Test.
Install breakout box, leave processor disconnected.
No ~ SERVICE open circuits.
DVOM on 200 ohm scale. RECONNECT all
components. RERUN
Measure resistance between sensor signal circuit Quick Test.
at the temperature sensor vehicle harness
connector and Test Pin 7 (ECT) or 25 (ACT/VAT)
a~ the breakout box.
Measure resistance between SIG RTN circuit at

the temperature sensor vehicle harness connector
and Test Pin 46 at the breakout box.
DA201 SERVICE CODE 61, 64 OR 68:

INDUCE OPPOSITE CODE 51, 54, or 58
Service codes 61 (ECT), 64(ACT or VAT) or 68(VAT), Yes ~ REPLACE sensor.

indicate that the corresponding sensor's signal is RECONNECT harness.
less than the Self-Test minimum. The ACT and ECT RERUN Quick Test.
sensor minimum is 0.2 volts. The VAT sensor
minimum is 0.35 volts. No ~ GO to IOA211.
Possible causes:
- Temperature too high (VAT).
- Grounded circuit in harness (ACT or ECT).
- Faulty sensor.
- Faulty processor.
- Faulty connection.
Disconnect vehicle harness from suspect sensor.
Inspect for damaged, corroded, pushed out pins
of loose wires, etc. Service as necessary.
Is code 51, 54, or 58 present?

ALL RIGHTS RESERVED
EEC-IVPinpoint Test Procedures 17-37

DA
TEST STEP . RESULT ~ ACTION TO TAKE
I
DA21 CHECK VREF CIRCUIT VOLTAGE AT
THROTTLE POSITION SENSOR
Refer to schematic in Pinpoint Test IDH I. Yes ~ RECONNECT TP

sensor, GO to IDA22 I "
Suspect temperature sensor disconnected. No ~ GO to Pinpoint Test
Step IC11.
Key on, engine off.
RTN circuit at the TP sensor vehicle sensor
connector.
Is Yoltage between 4.0 Yolts and 6.0 YOIts?
DA221 CHECK TEMPERATURE SENSOR S'IGNAL

CIRCUIT FOR SHORT TO GROUND
Key off s wait 10 seconds. Yes ~ REPLACE processor.

Suspect temperature sensor disconnected. RECONNECT all
Disconnect processor Pin 60 connector. Inspect components. RERUN
for damaged or pushed out pins s corrosion, loose Quick Test.
No ~ SERVICE short- circuit.
DVOM on 200,.0 ohm scale. RECONNECT all
components. RERUN
Measure resistance between Test Pin 7 (ECT) or Quick Test.
25 (ACT/VAT) and Test Pins 40, 46 and 60 at
the breakout box.
Is each .resistance greater than 10,000 ohms?

ALL RIGHTS RESERVED

DA
ACf, ECf and VAT Test
DA901 CONTINUOUS MEMORY CODE 51, 54, 58, 61,

I 64 OR 68: CHECK SENSOR
Continuous Memory codes 51, 54, and 58, indicate Yes ~ DISCONNECT and
that the sensor signal was greater than the Self- inspect connectors. If
Test maximum of 4.6 volts. The code was OK, REPLACE the
generated under normal driving conditions. sensor. CLEAR
Continuous Memory
Continuous Memory codes 61, 64, and 68, indicate (REFER to Quick Test
that the sensor signal was less than the Self-Test Appendix). RERUN
minimum of 0.2 volts. The code was generated Quick Test.
under normal driving conditions..
No ~ GO to IDA91 I.
Sensors Continuous Memory Codes
ACT 54 and 64
EeT 51 and 61
VAT 54, 58, 64 and 68
Possible causes:
- Faulty sensor.
- Open circuit in harness.
- Grounded circuit in harness.
- Faulty processor.
Enter Key On Engine Off continuous monitor
mode. -Refer to Quick Test Appendix.
Observe YOM or STAR LED for indication of a
fault while performing the following:
- Tap on the sensor to simulate road shock.
- Wiggle the sensor connector.
Is a fault indicated?
POWER OR
VREF CIRCUIT
r
~.}-SIGNAL-o y''' )~
~>-SIGRTN-o )( )~
PROCESSOR HARNESS ACT SENSOR
A9582C

ALL RIGHTS RESERVED
EEe-IV Pinpoint Test Procedures 1739 .
Temperature Sensor. Test .Pinpoint

DA
I
DA91 CHECK EEC-IV VEHICLE HARNESS
Still in Key On Engine Off continuous monitor . Yes ~ ISOLATE fault and
mode. SERVICE as necessary.
CLEAR Continuous
Observe VOM or STAR LED for fault indication Memory (REFER to
while performing the following: Quick Test Appendix).
RERUN Quick Test.
- Refer to the illustration in Step IDA90 I. Grasp
the vehicle harness close to the sensor
connector. Wiggle, shake, or bend a small No ~ GO to IOA92\.
section of the EEC-IV system vehicle' harness
while working your way to the dash panel. Also
wiggle, shake, or bend the EEC-IV system
vehicle harness from the dash panel to the
processor.
Is a fault Indicated?
DA921 CHECK PROCESSOR AND VEHICLE HARNESS

CONNECTORS
Key off, wait 10 seconds. Yes ~ . Unable to duplicate

and/or identify fault at
Disconnect processor Pin 60 connector. this time. For further
Disconnect sensor connector. Inspect for damage, dia3nosis using the
loose or pushed out pins, loose or poorly crimped EE -IV Monitor box,
wires. ' REFER to Section 18
EEC-IV Monitor Box:
Are connectors and terminals OK? Intermittent fault
Diagnosis.
All others, CLEAR

:
continuous memory
(REFER to Quick Test
Appendix). RERUN
..
Quick Test.
.' No ~ SERVICE as necessary.

CLEAR Continuous
Memory (REFER to
Quick Test Appendix).
RERUN Quick Test.

ALL RIGHTS RESERVED
Pinpoint
IMass Air Flow (MAF) Sensor Test
DC
INote I
You should enter this Pinpoint Test only when a Service Code 26, 56, or 66 Is received
during Quick Test or you have been directed here from Diagnosis By Symptom.
IRemember I
may be at fault:
Air cleaner element Throttle body

Inlet air duct
Mass Air Flow sensor (-128579-) Processor assembly (-12A650-)

Harness circuits: VPWR, PWR GND, MAF
and MAF RTN

2.3L, 2.9L AND 4.0L MA: TEST PIN 14 te'
ALL OTHERS: TEST PIN 50 ~
MAF
I
. O-+-IHj~
2.3L, 2.9L AND 4.0L MA: TEST PIN 15 t:"\...-
ALL OTHERS: TEST PIN 9 ~MAF RTN-- C ---jI-tHfo-fYI
TEST PIN 400 ~
TEST PIN 60@--PWR GNO---+B-oHMt-u.1
TEST PIN 37 @--VPWR
TEST PIN 57<!>-------J
------:A
MASS AIR FLOW (MAF)
SENSOR VEHICLE HARNESS
CONNECTOR
* TEST PINS LOCATED ON THE BREAKOUT BOX.

NOTE: ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE.
A11544C

ALL RIGHTS RESERVED
EEC-IV' Pinpoint Test Procedures 17-41
IMass Air Flow (MAF) Sensor Pinpoint

Test
DC
Test Pin 50 or 14 MAF

1.9L MA SEFI BA/BK
All Others DB/O
Test Pin 9 or 15 MAF RTN

1.9L MA SEFI GA/Y
All Others T/LB
Test Pin 40/60 PWR GND

1.9L MA SEFI BK/GA
All Others BK/LG
Test Pin 37/57 VPWR

1.9L MA SEFI W/A
All Others A

ALL RIGHTS RESERVED
Pinpoint
IMass Air Flow (MAP) Sensor Test
DC
NOTE: MAF Signal Voltage V8. engine operation condition while engine is at normal
operating temperature. These values are typical for automatics, but may vary
based on vehicle load and temperature.
MAF Sensor Graph
VOLTAGE
(V)
3.0
2.0
1.0
---- -
IDLE 20 mph 40 mph 60 mph
A8901-B
MAF Sensor Data

Engine Condition MAF Signal Voltage
IDLE .60
20 mph 1.10
40 mph 1.70
60 mph 2.10

ALL RIGHTS RESERVED
Pinpoint
IMass Air Flow (MAP) Sensor Test
DC
. TEST STEP RESULT ~ ACTION TO TAKE
DC1 ISERVICE CODE 26:

CHECK VPWR CIRCUIT VOLTAGE
..
Service Code 26 indicates that the Mass Air Flow Yes ~ GO to IOC21.
(MAF) sensor is out of Self-Test range. Key On
Engine Off Service Code 26 indicates that the MAF No , ~ RECONNECT MAF
Signal was greater than .70 volts during Key On, sensor. GO to Pinpoint
Engine Off Self-Test. Key On Engine Running Test Step 1811.
Service Code 26 indicates that the MAF Signal was
not between .20 and 1.50 volts during Key On
Engine Running Self-Test.
NOTE: Service Code 26 could be generated by
the garage exhaust ventilation system.
Remove ventilation system and. properly
vent to outside atmosphere before
rerunning SelfTest.
Possible causes:
- Faulty MAF sensor.
- Faulty processor
Key off.
Disconnect MAF sensor.
Key on, engine off.
Measure voltage between VPWR circuit at the
MAF sensor vehicle harness connector and
battery negative post. -
DC2 I CHECK MAF SENSOR GROUND
Key on, engine off. Yes ~ GO to IOC101.

MAF sensor disconnected.
No ~ SERVICE open PWR
DVOM on 20 volt scale. GND circuit
RECONNECT MAF
Measure voltage between VPWR circuit and PWR sensor. RERUN Quick
GND circuit at the MAF sensor vehicle harness Test.
connector.

ALL RIGHTS RESERVED
Pinpoint
DC
DC10 SERVICE CODE 66:

CHECK CONTINUITY OF MAF AND VPWR
CIRCUITS
Service Code 66 indicates that the Mass Air Flow Yes ~ GO to IOC111.
(MAF) sensor signal went below .40 volts during
normal engine operation (Continuous) or during Self- No ~ SERVICE open circuit.
Test. REMOVE breakout box.
RECONNECT all
Possible causes: components. RERUN
- Open MAF circuit. Quick Test.
- Open VPWR circuit to MAF sensor.
- Open PWR GND circuit to MAF sensor.
- Open MAF RTN circuit to MAF sensor.
- MAF circuit shorted to ground.
- Faulty Processor.
- Faulty MAF sensor.
- Air leak before or after MAF sensor.
- MAF sensor disconnected.
Key off.
for damaged or pushed out pins, corrosion, loose
w~res, etc. Service as necessary.

Measure resistance between VPWR circuit at the
MAF sensor vehicle harness connector and Test
For 2.3L, 2.9L or 4.0L MA:
Measure resistance between MAF circuit at the
For all others:
Measure resistance between MAF circuit at the

ALL RIGHTS RESERVED
. Pinpoint
DC
,
DC111 CHECK MAF CIRCUIT FOR SHORTS TO

GROUND AND MAF RTN CIRCUIT
Key off. Yes ~ GO to IDC121.

No ~ SERVICE short
circuit(s). REMOVE
DVOM on 200,000 ohm scale. breakout box.
RECONNECT all
For 2.3L, 2.9L or 4.0L MA: components. RERUN
Quick Test.
Measure resistance between Test Pin 14 and Test
Pins 15, 40 and 60 at the breakout box.
For all others:
. Is each resistance greater than 10,000 ohms?
DC121 CHECK CONTINUITY OF PWR GND CIRCUIT
Key off. Yes ~ GO to IOC131.

Breakout box installed, processor disconnected. REMOVE breakout box.
.. RECONNECT all
components. RERUN
Measure resistance between PWR GND circuit at Quick Test.
the MAF sensor vehicle harness connector and
battery negative post.
DC131 CHECK CONTINUITY OF MAF RTN CIRCUIT

I
Key off. Yes ~ GO to IOC141.

components. RERUN
For 2.3L, 2.9L or 4.0L MA: Quick Test.
Measure resistance between MAF R1"N circuit at
Test Pin 15 at the breakout box.
For all others:
Measure resistance between MAF RTN circuit at

ALL RIGHTS RESERVED
M_a_S_S_A_ir_F_IO_W_(_MAF
I...... __>_s_e_D_So_r 1 '---P_i;_:_:_:_D_t.. . . . . . . _D_C_.. . . .
DC14 CHECK MAF CIRCUIT FOR SHORT TO

GROUND
Key off. Yes ~ Go to IOC1SI.

No ~ REPLACE processor.
Connect processor to breakout box. RECONNECT MAF
sensor. RERUN Quick
DVOM on 200,000 ohm scale. Test.
For 2.3L, 2.9L or 4.0L MA:
For all others:
DC1S CHECK MAF CIRCUIT OUTPUT

Reconnect MAF sensor. RERUN Quick Test.
DVOM on 20 volt scale. No ~ REPLACE MAF sensor.
Key on, engine running. RECONNECT
For 2.3L, 2.9L or 4.0L MA: processor. RERUN
Quick Test.
Measure voltage between Test Pin '14 at the
breakout box and battery negative post.
. For all others:
I
Is voltage between .20 and 1.50 volts?
DC20 SERVICE CODE 56:

RERUN SELF-TEST WITH MAF SENSOR
DISCONNECTED
Key off. Yes ~ REPLACE MAF sensor.

RERUN Quick Test.
Start engine, idle one minute. No ~ GO to IOC211.
Key off.
Rerun Key On Engine Off Self-Test.
Is Service Code 66 present?

ALL RIGHTS RESERVED
Pinpoint
IMass Air Flow (MAP) Sensor
Test
DC
I
DC21 CHECK MAF CIRCUIT FOR SHORT TO VPWR

MAF sensor disconnected. RECONNECT MAF
Disconnect processor 60 pin connector. Inspect sensor. RERUN Quick
Test.
Install breakout box, leave processor disconnect~d.
. REMOVE breakout box.
components. RERUN
Measure resistance between MAF circuit and Quick Test.
VPWR circuit at the MAF sensor vehicle harness
connector.
Is resistance greater than 10,000 ohms?
..

ALL RIGHTS RESERVED
1748 ~EC.IV Pinpoint Test Procedures
EGR Valve Position Sensor (EVP) Pinpoint

DD
ControljVent (EGRC/EGRV) Test
INote I
You should enter this Pinpoint Test only when a Service Code 31, 32, 33, 34, 35, 83 or
84 is received during Quick Test.
IRemember I .
EVP sensor (-9G428-)
Harness circuits: EVP, SIG RTN, VREF, EGRV, EGRC, VPWR
EGRV/EGRC solenoids (-9D474-)
EGR Valve (-9H473-)
Vacuum lines (EGRVIEGRC, EGR)

*TEST PIN 26(!) OIW VREF--_~~~
EVP SENSOR
TEST PIN 27 (!) BRJLG EVP--.......a-t< VEHICLE
BKIW HARNESS
TEST PIN 46 (!) SIG RTN --++-.....c1 CONNECTOR
TO
TEST PIN 52 (!) Y EGRC EGRC EGRC/EGRV
VEHICLE
HARNESS
TEST PIN 37 G) R VPWR CONNECTORS
TO
TEST PIN 33 @ OG EGRV
EGRV

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A9583D

ALL RIGHTS RESERVED
EGR Valve Position ~ensor (EVP) Pinpoint

Test-
DD
Control/Vent (EGRC/EGRV)
NOTE: Voltage values calculated for VREF = 5.0 volts (These values may vary 15
percent due to sensor and VREF variations.)
EVP Sensor Graph
%EGA
100%
800/0
40%
20%
0% L--~~---4-----+------+--"-"-----+----~
Ov 1v 2v 3v 4v 5v
Voltage Reading (volts)

A8902A
EVP Sensor Data
% EGA VOLTAGE
0 0.40
10 0.75
20 1.10
30 1.45
40 "1'.80
50 2.15
60 2.50
70 2.85
80 3.20
90 3.55
100 3.90

ALL RIGHTS RESERVED

DD
ControlfVent (EGRC/EGRV) Test
DD1 ENGINE RUNNING SERVICE CODE 31:

RUN ENGINE RUNNING SELF-TEST WITH
EGR VACUUM SIGNAL LINE DISCONNECTED
AT EGR VALVE
Engine Running Service Code 31 indicates that Yes ~ GO to 10021.

dUring the Engine Running Self-Test, the EVP
sensor signal to the processor is not in the
expected range with the EGR valve closed.
No ~ RECONNECT EGR
lacuuT line. GO to
Possible causes are: 0011 .
- Faulty EGRC/EGRV solenoids.
- Clogged EGRV filter.
Key off.
Disconnect EGR vacuum line at EGR valve and
cap EGR vacuum line.
Rerun Engine Running Self-Test.
Is Code 31 present (ignore all other codes)?
DD2 KEY ON ENGINE OFF SERVICE CODE 31:

CHECK EVP SENSOR RESISTANCE WHILE
APPLYING VACUUM TO EGR VALVE
Key On Engine Off Service Code 31 indicates that Resistance ~ RECONNECT EGR
the EVP sensor signal to the ~rocessor is not in ~radUallY racu,m line. GO to
the expected range with the GR valve closed. ecreases from 003 .
Possible causes are: no greater than
550 ohms to
- Open or shorted circuit. no less than
- Faulty EGR valve. 100 ohms
- Faulty EVP sensor.
- Faulty processor.
Resistance is ~ REPLACE EVP sensor.
less than 100 RECONNECT EGR .
Key off. ohms or vacuum line. RERUN
Disconnect EGR vacuum line at EGR valve and ~reater than Quick Test.
cap EGR vacuum line. 500 ohms
Disconnect EVP sensor.
Resistance ~ GO to 100141.
does not
Connect vacuum pump to EGA valve. decrease or
unable to hold
Measure resistance between EVP circuit and vacuum
VREF circuit at the EVP sensor while sraduall Y
increasing vacuum to 33 kPa (10 in-Hg .
Observe resistance as vacuum increases.
VREFy
SIG.RTN.
_EVP
EVP
SENSOR
A8903-A

ALL RIGHTS RESERVED
EGR Valve Position Sensor (EVP). Pinpoint

DD
Control/Vent (EGRC/EGRV) Test
0031 CHECK VREF CIRCUIT VOLTAGE AT THE EVP

Key on, engine off. Yes ~ GO to 10041.

EVP sensor disconnected.
DVOM on 20 volt scale. Step IC11.
RTN circuit at the EVP sensor vehicle harness
connector.
Is voltage between 4.0 and 6.0 volts?
OIW-VREF ""-J:1
EVPSENSOR
BRlLG-EVP
BKlW-SIG. RTN
r:
L:
o1:t] VEHICLE
HARNESS
CONNECTOR
A8904-B
004 I CHECK EVP CIRCUIT CONTINUITY .
Key off. ' Yes ~ GO to 10051.

Disconnect processor 60 pin connector. Inspect REMOVE breakout box.
for damaged or pushed out pins, corrosion, loose RECONNECT all
wires, etc. Service as necessary. components. RERUN
Quick Test.
breakout box and EVP circuit at the EVP sensor

ALL RIGHTS RESERVED

DD
0051 CHECK EVP CIRCUIT FOR SHORTS TO VREF

CIRCUIT AND GROUND

RECONNECT all
DVOM on 200,000 ohm scale. components. RERUN
Measure resistance between Test Pin 27 and Test Quick Test.
Pins 26, 40, 46 and 60 at breakout box.
OD6 I SUBSTITUTE EVP SENSOR AND EGR VALVE

Electrically connect known good EVP sensor and CONNECT original EVP
EGR valve assembly. sensor and EGR valve
assembly. RERUN
Quick Test.
Connect processor to breakout box.
Perform Key On Engine Off Self-Test. No ~ GO to 10071.
Is Code 31 present?
0071 CHECK ORIGINAL EVP SENSOR ON

SUBSTITUTED EGR VALVE
Key off. Yes ~ INSTALL new EVP

sensor with original
Breakout box installed. processor connected. EGR valve. REMOVE
Install original EVP. sensor on known good EGR breakout box.
valve. RECONNECT
processor. RERUN
Connect vehicle harness to EVP sensor. Quick Test.
Is Code 31 present? RECONNECT
processor. REFER to
EGR System, Section
6.

ALL RIGHTS RESERVED

DD
0011 ENGINE RUNNING SERVICE CODES 32/33/34: ,

CHECK FOR VACUUM CYCLING' AT EGR
VALVE
Engine Running Service Codes 32/33/34 indicate Yes ~ REMOVE vacuum

that when instructed by the processor, the EGR gauge. GO to 100131.
system was unable to either open the EGR valve
(34), hold the valve open (32), or close the valve
properly (33).
No ~ If vacuum did not
increase:
Possible causes are: REMOVE vacuum
- Faulty vacuum lines. gauge. GO to 100121.
- Clogged EGRV filter. . If vacuum did
- Faulty EVP sensor. increase, but did not
return to less than 1
- Faulty EGR valve. in-Hg within 10
- Faulty EGRC/EGRV solenoids. seconds:
- Faulty processor. CHECK EGRV filter for
obstructions. SERVICE
Key off. as necessary. If OK,
Disconnect EGR vacuum line at the EGR valve. REPLACE solenoid
assembly.
Connect a vacuum gauge to the EGR vacuum RECONNECT all
line, leaving the EGR valve disconnected. vacuum lines. RERUN
While observing vacuum gauge, rerun Engine Quick Test.
Running Self-Test. ..
During test, does vacuum reading:
- Increase from less than 1 in-Hg to greater
than 5 in-Hg?
- And, within 10 sec:onds, return to less than
1 in-Hg?
NqTE: Disregard code output at this time. . .
0012 CHECK VACUUM SUPPLY TO EGRC/EGRV

SOLENOIDS
Key off. Yes ~ CHECK vacuum line

Disconnect the vacuum source to the EGRCI from EGRCIEGRV
EGRV solenoids. solenoids to EGR valve
for kinks, obstructions
Install a vacuum gauge at source vacuum line. or leaks. If OK,
Start engine and check vacuum. REPLACE solenoid
assembly.
Is vacuum greater than 33 kPa (10 in-Hg)? RECONNECT all
vacuum lines. RERUN
Quick Test.
No ~ CHECK source vacuum

line to EGRCIEGRV
solenoids. SERVICE as
necessary.
RECONNECT all
vacuum lines. RERUN
Quick Test.

ALL RIGHTS RESERVED

DD
00131 CHECK EVP SENSOR. RESISTANCE WHILE

APPLYING VACUUM TO EGR VALVE

RECONNECT EVP
Disconnect EVP sensor. Inspect for damaged pins, sensor and EGR
corrosion, and pins pushed out. Service as vacuum line. RERUN
necessary. Quick Test.
Disconnect EGR vacuum line at EGR valve.
No ~ GO to 100141.
Connect vacuum pump to EGR valve.
Measure resistance between EVP circuit and
VREF circuit at the EVP. sensor while increasing
vacuum to 33 kPa (10 in-Hg).
Does the resistance gradually change between
5500 and 100 ohms?
00141 MANUALLY EXERCISE EVP SENSOR
Key off. Yes ~ RECONNECT EVP

sensor and EGR supply
EVP sensor disconnected. vacuum line. REFER to
Remove EVP sensor from EGR valve. EGR System, Section
6.
VREF circuit at the EVP sensor while gradually
applying pressure to EVP sensor shaft.
No ~ REPLACE EVP sensor.
RECONNECT EGR
Observe resistance as shaft is slowly pushed in vacuum line. RERUN
and slowly released. Quick Test.
NOTE: It Is normal for the EVP sensor total

resistance to drop below 100 ohms when
disconnected from the EGR valve. A
defective part will change resistance
suddenly between 5500 and 100 ohms.
Does the resistance change gradually between
5500 and 100 ohms?

ALL RIGHTS RESERVED
EGR Valve -Position Sensor (EVP) Pinpoint

-Test
DD
ControlfVent (EGRC/EGRV)
00171 SERVICE CODE 83/84:

CHECK EGRV/EGRC SOLENOID RESISTANCE
Service Code 83 indicates an EGRC circuit failure. Yes ~ GO to 100181.

Service Code 84 ind.icates an EGRV circuit failure.
No ~ REPLACE EGRC/EGRV
Possible causes are: solenoid assembly.
,
RERUN Quick Test.
- Open or shorted circuit.
- Faulty EGRC/EGRV solenoid.
- Faulty processor.
Key off.
Disconnect EGRC/EGRV solenoids. Inspect for
damaged pins, corrosion and pins pushed out.
Service as necessary.
_ Measure resistance between EGRV circuit and
VPWR circuit at the EGRV solenoid.
Measure resistance between EGRC circuit and
VPWR circuit at the EGRC solenoid.
Is each resistance between 30 and 70 ohms?
00181 CHECK VPWR CIRCUIT VOLTAGE AT

EGRC/EGRV SOLENOIDS
EGRC/EGRV solenoids disconnected. Yes ~ GO to 100191.

DVOM on 20 vol'- scale.
No .. ~ SERVICE open circuit.
Key on, engine off. RECONNECT EGRCI
EGRV solenoids.
Measure voltage between battery negative post
and VPWR circuit on both EGR solenoid vehicle . RERUN Quick Test.
harness connectors.
Is each voltage greater than 10.5 volts?
r=i!...ro
-EGRC .:r;Fll EGRC EGRC/EGRV
VEHICLE
HARNESS
R-VPWR c-=1 CONNECTORS
DG-EGRV '~1O
- EGRV
A8905-A

ALL RIGHTS RESERVED

DD
00191 CHECK CONTINUITY OF EGRC/EGRV

CIRCUITS

EGRC/EGRV solenoids disconnected.
Quick Test.
breakout box and EGRV circuit at the EGRV
solenoid vehicle harness connector.
breakout box and EGRC circuit at the EGRC
00201 CHECK EGRC/EGRV CIRCUITS FOR SHORTS

TO GROUND

EGRC/EGRV solenoids disconnected.
RECONNECT all
components. RERUN
Pins 40, 46, and 60 at the breakout box.

ALL RIGHTS RESERVED
EGR yalve Position Sensor (EVP) Pinpoint

"DO
00211 CHECK EGRC/EGRV CIRCUITS FOR SHO~TS

TO POWER . .

EGRC/EGRV solenoids disconnected. RECONNECT all
Breakout box installed, processor disconnected. components. RERUN
Quick Test.
Measure resistance between Test Pin 33 and Test No. ~ SERVICE short circuit.
Pins 37 and 57 at the breakout box. REMOVE breakout box.
RECONNECT all
Measure resistange between Test Pin 52 and Test components. RERUN
Pins 37 and 57 at the breakout box. Quick Test. If code is
repeated, REPLACE
Is each resistance greater than 10,000 ohms? processor.
I
0030 SERVICE CODE 35:
CHECK FOR CODE 12
Service Code 35 indicates that the engine rpm was Yes ~ GO to IKE11.
too low to perform the .E~R test.
Possible' causes are: No ~ GO to 100311.
- Faulty ISC system

- Faulty processor
Is Code 12 also present?
00311 RETEST AT 1,500 RPM
Key off. Yes -. ~ REPLACE processor.

RERUN Quick Test.
Install tachometer.: '.
:.
Rer~n Engine Running Self-Test while maintaining No ~ RERUN Quick Test.

1,500 rpm. SERVICE any other
codes as necessary.
Is Code 35 still present (ignore all other
codes.)?

ALL RIGHTS RESERVED

DD
ControljVent (EGRCjEGRV) Test
00901 CONTINUOUS MEMORY CODE 31:

EXERCISE EVP SENSOR
Continuous Memory Code 31 indicates that Yes ~ GO to 100911.

sometime during vehicle operation, the EVP signal
was out of Self-Test range. No ~ GO to 100921.
Possible causes are:
- Open or shorted circuit
- Faulty EVP sensor
Enter Key On Engine Off Continuous Monitor
Mode. Refer to Quick Test Appendix.
Observe VOM or STAR LED for indication of a
Connect a vacuum pump to the EGR valve.
Very slowly apply 20 kPa (6 in-Hg) vacuum to the
EGR valve.
Slowly bleed vacuum off the EGR valve. Lightly
tap on EVP sensor (simulate road shock).
Wiggle EVP sensor vehicle harness connector.
[~Jr/VREF~~
~VP
', ~>") ., SIG:O
SIG.RTN~
PROCESSOR EVP SENSOR
HARNESS
A9584-B
00911 MEASURE EVP SIGNAL VOLTAGE

WHILE EXERCISING EVP SENSOR
Key off. Yes ~ DISC'ONNECT and

Disconnect processor 60 pin connector. Inspect INSPECT connector. If
for damaged or pushed out pins, corrosion, loose connector and
wires, etc. Service as necessary. terminals are ~OOd,
REPLACE EV sensor.
Install breakout box and connect processor to CLEAR Continuous
breako'ut box. Memory (REFER to
Connect a DVOM between Test Pin 27 and Test Quick Test Appendix).
Pin 46. RERUN Quick Test.
Re-enter Key On Engine Off Continuous Monitor No ~ EGR valve overshoot
Mode. may have caused
While observing DVOM, repeat Test Step 10090 I. Continuous Memory
Code 31. Sensor
Does the fault occur below 4.25 volts? service is not required.
To verify vehicle
harness integrity, GO
to 100921.

ALL RIGHTS RESERVED

DD
ControlfVent (EGRC/EGRV) Test
00921 CHECK EEC-IV HARNESS I
Observe YOM or STAR LED for a fault indication Yes ~ ISOLATE fault and
while performing the following: SERVICE- as necessary.
REFER to appropriate
Referring to the illustration in Step I0090 I, grasp figure. CLEAR
the harness closest to the sensor connector. Continuous ~emory
Wiggle, shake or bend a small section of the (REFER to Quick Test
EEC~IV system vehicle harness while working your Appendix). RERUN
way to the dash panel. Also wiggle, shake or Quick Test.
bend the EEC-IV vehicle harness from the dash
panel to the processor. No ~ GO to 100931.
00931 CHECK PROCESSOR AND VEHICLE HARNESS

CONNECTORS
Key off. Yes ~ Unable to duplicate

Disconnect processor 60 pin connector. this time. For further
Inspect both connectors and connector terminals diagnosis using the
EEC-IV Monitor box,
for obvious damage or faults.
REFER to Section 18
Are connectors and terminals OK? EEC-IV Monitor Box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.
No ~ SERVICE as necessary.
CLEAR Continuous
Memory (REFER to
RERUN Quick Test.
\
.

ALL RIGHTS RESERVED
Manifold Absolute Pressure (MAP)/ Pinpoint

DF
Barometric Pressure (BP) Sensor Test
INote I
You should enter this Pinpoint Test only when a Service Code 22 or 72 Is received
during Quick Test or If you have been directed here from Pinpoint Test 00 or
Diagnosis By Symptom.
IRememberI
may be at fault:
Unusually high/low barometric pressure.
Kinked or obstructed vacuum lines (MAP).
Basic engine (valves, vacuum leaks, timing, EGR valve, etc.).
MAP/BP sensor (-9F479-)
Harness circuits: VREF, MAP/BP SIG, and SIG RTN
MAP vacuum line

ALL RIGHTS RESERVED
Manifold Absolute Pressure (MAP)/ pinpoint

DF
*TEST PIN 46 E ) l o - - - - - - - S I G RTN ----<'<~-~
TEST PIN 45 E ) - - - - - - - M A P / B P SIG ---~-'1.----l~
TEST PIN 26 e-------VREF-----...(~~--

MAP/BP SENSOR
VEHICLE
HARNESS
CONNECTOR
TO MAP/BP TO
SENSOR, ; MAP/BP
VEHICLE SENSOR
HARNESS
CONNECTOR
o Q. a:
a: ~n~
o Q. CI)
U. <w
::E~
+

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFAC~. A9588-D

ALL RIGHTS RESERVED
Manifold Absolute -Pressure (MAP)/ Pinpoint

DF
Test Pin 45 MAP/BP SIG

2.9L Scorpio BR/Y
2.3L Ranger/Supercab
2.9L Ranger/Bronco II
3.0L Aerostar
4.0L Aerostar
4.0L Ranger
3.8L SC
3.8L RWD DB/LG
4.9L E-Series
5.0L E-Series
5.8L E-Series
7.5L E-Series
7.3L E-Series Diesel
5.0L Mark VII
3.0L Probe W/GR
All Others LG/BK
Test Pin 46 SIG RTN

1.9L MA SEFI LG/BK
2.9L Scorpio BR
7.5L F-Series
7.3L F-Series Diesel
3.0L Probe LG/Y
All Others BK/W
Test Pin 26 VREF

1.9L MA SEFI R/W
2.9L Scorpio BR/BK
5.8L F-Series/Bronco BR/W
7.5L F-Series
3.0L Probe LG/R
All Others O/W

ALL RIGHTS RESERVED
EEC-IV Pinpoint Test Procedures
Manifold Absolute Pressure (MAP)/ .Pinpoint

DF
MAP Sensor. Graph ..

NOTE: MAP sensor output frequency versus' manifold vacuum data is based on 30.0
in-Hg barometric pressure. '
in. kPa MANIFOLD VACUUM
(Hg)
o o
3 10.2
6 20.3
9 30.5
12 40.6
15 50.8
18 61.0
21 71.1
24 81.3
27 91.5
30 101.6 --__l__-~-__ll__-_+_-_~-_+_-_I__-_+_-__ll__
60 80 100 . 120 140 160
MAP SENSOR O~TPUT F~EQUENCY (Hz) A9207-B
MAP Sensor Data

Manifold Vacuum Frequency
In-Hg kPa Hz
0 0 . 159
3 10.2 150
6 20.3 ' 141
9' 30.5 133
12 40.6 125
15 50.8 117
18 61.0 109
21 71.1 102
24 81.3 95
'27 91.5 88
30 101.6 80

ALL RIGHTS RESERVED

DF
MAP/BP Sensor Graph (KOEO)

NOTE: Frequency may vary plus or minus 3 Hz from the values given due to sensor
variations.
MAP/SP
FREQUENCY (Hz)
165
160 ----=~---------------------____:: ~
155 .........-:::
150
145
140
G ~
3HZ
.........-:::~
EXAMPLE:
~~
............:""""""'y
135 ......-:::::: :::,....--:::::::--. AT A BAROMETRIC PRESSURE OF
130 ~ 101.3 kPa, THE BP SENSOR
125 ", ~ ~ T OUTPUT FREQUENCY WILL BE
~ 159Hz3Hz
120 ---I"",",""mr,~"'"'''""''''"''~"'''"""",'''''''''"",",,,,"",T'ITI''I~ITrTI'',",,"",,''''''''''ITrTI'''"'"'"'"'ft'TTIrTT'IT",",","n--
M~~oo~M~~ron~~~oo~~~~oo~~~~mm~~
BAROMETRIC PRESSURE (kPa) A9208B
MAPIBP Sensor Data
Barometric Pressure Frequency

In-Hg kPa Hz
17.1 58 122.4
18.3 62 125.5
19.5 66 128.7
20.7 70 131.9
21.8 74 135.1
23.0 78 138.3
24.2 82 141.8
25.4 86 145.4
26.6 90 148.9
27.7 94 152.5
28.9 98 156.1
30.1 102 159.6
31.0 105 162.4

ALL RIGHTS RESERVED
,Manifold Absolute Pressure (MAP)/. ( Pinpoint'

DF
! TEST STEP . RESULT ~ ACTION TO TAKE
DF1 ISERVICE CODE 22:

CHECK FOR POWER TO MAP/BP SENSOR
I Service Code 22 indicates that the Manifold Yes ~ GO to IOF31.

Absolute Pressure (MAP)/Barometric Pressure (BP)
sensor is out. of Self-Test range. Correct MAP/BP
tester range of measurement is typically from 1.4 to
No ~ GO to IOF21.
1.6 volts.
Possible causes:
- MAP/BP SIG circuit open between sensor
vehicle harness connector and processor.
- MAP/BP SIG circuit shorted to VREF, SIG RTN,
or GND.
- Faulty MAP/BP sensor. .. ~
- Vacuum trapped at MAP/BP sensor.

- High atmospheric pressure.
- Faulty processor.
- VREF circuit open at MAPIBP sensor.
- SIG RTN circuit open at MAPIBP sensor.
Key off.
Disconnect the MAPIBP sensor from the vehicle
harness.
Connect the MAPIBP tester between the vehicle
harness connector and the MAP/BP sensor. . ,
Insert MAP/BP banana plugs into DVOM. -. . -

Set DVOM to 20 volt scale.
NOTE: Green light on tester Indicates VREF Is
OK (4-6v). Red light (or no light) indicates
VREF Is either too low or too high.
.. .
Key on. ".
;
Is green light on?
DF21 CHECK FOR POW'ER AT SENSOR VEHICLE'

HARNESS CONNECTOR
~
' t
NOTE: Green light reaffirms that VREF is OK Yes .. REPLACE MAPIBP

(4-6v). Red light (or no light) Indicates sensor. RER~N Quick
VREF Is either too low or too high. Test.
Key on.
MAP/BP tester connected. No ~ REMOVE MAP/BP
tester. RECONNECT
DVOM connected to MAP/BP tester. the MAP/BP sensor.
Disconnect MAP/BP sensor. GO to Pinpoint Test
Step IC11.
Is green light on? .

ALL RIGHTS RESERVED

DF
DF3 I CHECK MAP/BP SENSOR OUTPUT
NOTE: Measure several known good MAP/BP Yes ~ REMOVE MAP/BP

sensors on available vehicles. The tester. GO to IDF41 .
measured voltage will be typical for your
location on the day of testing. No ~ REMOVE MAP/BP
Key on. tester. GO to IDFSI.
MAP/BP tester connected.
DVOM connected to MAPIBP tester.
Measure MAP/BP sensor voltage on customer
vehicle.
Is DVOM voltage in range for your altitude?
Approximate Altitude Voltage Output

(Ft.) (+1- .04 Volts)
o 1.59
1000 1.56
2000 1.53
3000 1.50
4000 1.47
5000 1.44
6000 1.41
7000 1.39
DF41 CHECK CONTINUITY OF MAP/BP SIG

CIRCUIT

. REMOVE breakout box.
MAPIBP sensor disconnected. RECONNECT MAPIBP
for damaged or pushed out pins, corrosion, loose Test.
Install breakout box, leave processor disconnected. REMOVE breakout box.
components. RERUN
Measure resistance between MAP/BP SIG circuit Quick Test.
at the MAPIBP sensor vehicle harness connector
and Test Pin 45 at. th~ breakout box.

ALL RIGHTS RESERVED

DF
.Barometric Pressure (BP) Sensor . Test
TEST STEp RESULT ~ ACTION TO TAKE
DF51 CHECK MAP/BP SIG CIRCUIT FOR SHORTS

TO VREF, SIG RTN AND GROUND
.-
Key off, wa~t 10 seconds. Yes ~ REPLACE MAPIBP
sensor. REMOVE
MAP/BP sensor disconnected. breakout box.
.. RECONNECT
processor. RERUN
Quick Test.
Install breakout box, leave processor disconnected. No ~ SERVICE short circuit.
DVOM on 200,000 ohm scale. REMOVE breakput box.
RECONNECT all
.Measure resistance between Test Pin 45 and Test components. RERUN
Pins 26, 46, 40 and 60 at the breakout box. Quick Test.
;
DF71 ENGINE RUNNING SERVICE CODE 22:

CHECK FOR EGR SERVICE CODES .
Service Code 22 (KOER) indicates the MAPI BP Yes ~ GO to Quick Test Step
signal is out of range for Engine Running Self-Test. 7.0 for appropriate
Pinpoint Test.
Possible causes:
- Faulty MAPIBP sensor. No ~ GO to IOFSI.
- Faulty v~cuum hoses.
- "Excess EGR.
Are Engine Running Service Codes 31, 32, 33,
34 or 35 present?
DF8 I CHECK MAP SENSOR OPERATION
Key off, wait 10' seconds. Yes ~ RELEASE vacuum. GO

to IOF91.
Disconnect vacuum supply hose from MAP sensor.
Install vacuum pump to MAP sensor. No ~ REPLACE MAP sensor.
CONNECT vacuum
Apply 18 in-Hg vacuum to MAP sensor. supply hose to MAP
Does MAP sensor hold vacuum? sensor. RERUN Quick
Test.

ALL RIGHTS RESERVED
1768 EEC-IV Pinpoin~ Test Procedures

DF
DF91 ATIEMPT TO ELIMINATE ENGINE RUNNING

SERVICE CODE 22
Key off, wait 10 seconds. Yes ~ REPLACE MAP sensor.

CONNECT vacuum
Plug MAP sensor vacuum supply hose. supply hose to MAP
Start engine and maintain 1500 100 engine rpm. sensor. RERUN Quick
Test.
Slowly apply 15 in-Hg vacuum to MAP sensor.
While maintaining rpm, perform Engine Running
Self-Test.
No ~ INSPECT vacuum
supply hose to MAP
Is Engine Running Service Code 22 still sensor. SERVICE as
present? necessary. If OK,
SERVICE other Engine
NOTE: Disregard any other Service Codes at this Running Service Codes.
time. If none, GO to
Diagnostic Routines,
Section 2 for a low
vacuum problem.
I
DF10 SERVICE CODE 72:
RERUN DYNAMIC RESPONSE TEST
Service Code 72 indicates that the MAP sensor Yes ~ GO to IDF111 .

output did not change enough during the Dynamic
Response Test.
No ~ SERVICE other Service
Possible causes: Codes as necessary. If
none, testing complete.
- System failed to detect partial WOT.
- MAP sensor vacuum supply hose improper
routing, blockage and/or linkage.
- Faulty MAP sensor.
Rerun Engine Running Self-Test. Be sure a
complete WOT is performed during the Dynamic
Response portion of the test.
Is Engine Running Service Code 72 still
present?
DF11 I CHECK VACUUM HOSES
Key off. Yes ~ GO to IDF121.

Check vacuum hoses for proper routing. Refer to
VECI decal. Check MAP sensor vacu~m supply No ~ SERVICE vacuum
hoses for disconnections, kinks or blockage. hoses as necessary.
RERUN Quick Test.
Are vacuum hoses OK? :

ALL RIGHTS RESERVED

DF
DF121 CHECK MAP SENSOR OPERATION
Key off, wait 10 seconds. Yes ~ RELEASE vacuum.

REMOVE vacuum
Disconnect vacuum supply hose from MAP sensor. pump. RECONNECT
Install vacuum pump to MAP sensor. vacuum supply hose to
MAP sensor. GO to
Apply 18 in-Hg vacuum to MAP sensor. IOF131.
Does MAP sensor hold vacuum?
No ~ REPLACE MAP sensor.
RECONNECT vacuum
supply hose to MAP
sensor. RERUN Quick
Test.
DF131 CHECK THAT VACUUM TO MAP SENSOR

DECREASES DURING DYNAMIC RESPONSE
Key off, wait 10 seconds. Yes ~ REPLACE MAP sensor.

" REMOVE vacuum
Tee ~ vacuum gauge in the intake manifold gauge. RERUN Quick
vacuum supply hose at the MAP sensor. Test.
Perform Engine Running Self-Test while observing '.
vacuum. No ~ EEC-IV system OK.
REFER to Engine Shop
Did vacuum decrease by more than 10 in-Hg Manual Group for
vacuum during Dynami<: Response test? probable causes
affecting engine
vacuum.

ALL RIGHTS RESERVED

DF
I
DF90 CONTINUOUS MEMORY CODE 22:
EXERCISE MAP/BP SENSOR
Continuous Memory Service Code 22 indicates the Yes ~ DISCONNECT and

Manifold Absolute Pressure (MAP)/Barometric INSPECT connectors. If
Pressure (BP) sensor was out of self-test range. connector and
The code was set during normal driving conditions. terminals are good,
REPLACE MAPIBP
Correct range of measurement is typically from 1.4
sensor. RERUN Quick
to 1.6 volts. Test.
Possible causes:
- Faulty MAP/BP sensor. No ~ GO to IDF91 I.
- Faulty EEC-IV vehicle harness..

- Faulty MAPIBP sensor vehicle harness
connectors andlor terminals.
- Unusually high/low barometric pressure.
Using Key On, Engine Off Continuous Monitor
Mode, observe VOM or STAR LED for indication
of a fault while performing the following:
- Connect a vacuum pump to the MAPIBP
sensor.
- Slowly apply 84 kPa (25 in-Hg) vacuum to the
MAP/BP sensor.
- Slowly bleed vacuum off the MAP/BP sensor.
- Lightly tap on MAP/BP sensor (simulate road
shock).
- Wiggle MAP/BP connector.
Is fault Indicated?
~
yVREF~~
~AP/BP<> ~>.. )EJ
PROCESSOR
SIG.RTN.~
MAP/BP SENSOR
HARNESS A8589-C

ALL RIGHTS RESERVED

DF
Barometric Pressure (BP) Sensor . Test'
I
DF91 CHECK EEC-IV VEHICLE HARNESS
Remain in Key On, Engine Off Continuous Monitor Yes ~ ISOLATE fault and
Mode. SERVICE as necessary.
CLEAR Continuous
Observe YOM or STAR LED for a fault indication Memory Code (REFER
while performing the following: to Quick Test
Appendix). RERUN
- Referring to the illustration in Step IDF90 I, Quick Test.
grasp the vehicle harness closest to the
sensor connector. Wiggle, shake or bend a
small section of the EEC-IV system vehicle No ~ GO to IDF921.
harness while working your way to the dash
panel. Also wiggle, shake or bend the EEC-IV
processor.
I
DF92 CHECK PROCESSOR AND VEHICLE HARNESS
CONNECTORS
Key off, wait 10 seconds. No ~ SERVICE as necessary.

RERUN Quick Test.
Disconnect processor 60 pin connector.
Inspect connectors and connector terminals for Yes ~ Unable to duplicate
obvious damage or faults. and/or identify fault at
this time. For further
Are connectors and terminals OK? diagnosis using the
EEC-IV monitor box,
REFER to Section 18
EEC-IV Monitor Box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.

ALL RIGHTS RESERVED
17-72 EEe-.V Pinpoint Test Procedures
Pinpoint
IKnock Sensor Test
DG
INote I
You should enter this Pinpoint Test only when a Service Code 25' is received during
Quick Test or If you have' been directed here from Diagnosis By Symptom.
IRemember I
may be at fault:
Fuel (quality)
Basic engine
Spark timing
Knock sensor (-12A699-)
Harness circuits: KS and SIG. RTN

-TEST PIN 23 0---KS------(~~ ....- - - -
A-KS
~SIGRTN
KNOCK
TEST PIN 46 G)~--SIG RTN -----(~~---~
KNOCK SENSOR SENSOR
CONNECTOR
ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A9590-D
Test Pin 23 KS Test Pin 46 SIG RTN

Car: 1.9L MA SEFI LG/BK
2.3L OHC MA
2.9L Scorpio BA
2.3L OHC Y/A
3.0L SHO-MA 4.9L F-Series/Bronco
3.8L SC 5.0L F-Series/Bronco
Truck: 5.8L F-Series/Bronco GY/A
4.9L/5.0L F-Series 7.3L F-Series Diesel
4.9L/5.0L E-Series LG/BK
All Others BK/W

ALL RIGHTS RESERVED
Pinpoint
IKnock Sensor Test
DG
DG1 I SERVICE CODE 25:

GENERATE KNOCK MANUALLY
Service Code 25 indicates that the Knock Sensor Yes ~ GO to IOG21.

(KS) signal to the processor was not sensed dur.ing
the Dynamic Response Test after the I.D. code in No ~ Knock Sensor system
Key On Engine Running Self-Test. OK. RERUN Engine
Running Self-Test and
Possible causes are: SERVICE any other
- Faulty Knock Sensor. codes.
- Open or shorted harness.

- Faulty processor. ,
NOTE: Since knock conditions are sensitive to
fuel, altitude and weather in addition to
ignition timing, perform Step IOG 11 before
servicing any components.
Loc~te Knock Sensor and prepare to rap/tap on
.exhaust manifold with a 4 oz. hammer.
Run Engine Running Self-Test (engine must be at
operating temperature).
\
Tap exhaust manifold directly above the knock

sensor immediately after the Dynamic Response \
code is given.
NOTE: It is not necessary to "goose" the
throttle. Ignore all other codes except
Code 25.
Is Servic~ Code 25 present?
DG21 CHECK KS CIRCUIT VOLTAGE

)
Key off, wait 10 seconds. Voltage is ~ .GO to IOG61.

between
Disconnect Knock Sensor. 1 and 4 volts
Key on, engine off.
Voltage is less ~ GO to IOG3.1.
than 1 volt
Measure voltage between KS circuit and SIG RTN
circuit at the Knock Sensor vehicle harness Voltage is ~ GO to IOG51.
connector. greater than 4
volts

ALL RIGHTS RESERVED
Pinpoint
IKnock Sensor Test
DG
DG31 CHECK CONTINUITY OF KS 'AND

SIG RTN CIRCUITS
Key off, wait 10 seconds. Yes ~ GO to IOG41.

components. RERUN
Knock Sensor disconnected. Quick Test.
Measure resist~nce between SIG RTN circuit at
the Knock Sensor vehicle harness connector and
Measure resistance between KS circuit at the
Knock Sensor vehicle harness connector and Test
Is each resistance less than S.O ohms?
DG4 I CHECK KS CIRCUIT FOR SHORT TO GROUND

Breakout box installed, processor disconnected. RECONNECT
rrocjssor. GO to
Knock Sensor disconnected. DG6 . ,
. DVOM on 200,000 ohm scale.
Measure resistance between Test Pin 23 and Test No ~ SERVICE short circuit.
Pins 40, 46 and 60 at the breakout box. REMOVE breakout box.
Is each resistance greater than 10,000 ohms? RECONNECT all
components. RERUN
Quick Test.
DGSI CHECK KS CIRCUIT FOR SHORT TO

VOLTAGE

Disconnect processor 60 pin connector. Inspect RECONNECT
for damaged or pushed out pins, corrosion, loose processor. GO to
wires, etc. Service as necessary. IDG61.
. .
Knock Sensor disconnected.
DVOM on 20 volt scale. RECONNECT all
Key on, engine off. components. RERUN
Quick Test.
Is Yoltag~ less than O.S Yolts?

ALL RIGHTS RESERVED
Pinpoint
IKnock Sensor Test
DG
DG61 TEST PROCESSOR WITH SUBSTITUTE KNOCK

SENSOR
Key off, wait 10 seconds. "Yes ~ REPLACE processor.

RECONNECT original
Connect a known good Knock Sensor to the Knock Sensor. RERUN
vehicle harness. Do not install this sensor on the Quick Test.
engine.
Run Engine Running Self-Test. (Engine must be at
operating temperature).
No . INSTALL new Knock
Sensor. RERUN Quick
Test.
Tap the substitute Knock Sensor with a 4 oz.
hammer immediately after the Dynamic Response
code is given.
NOTE: It Is not necessary to "goose" the
throttle. Ignore all other codes except
Code 25.

ALL RIGHTS RESERVED
Pinpoint
Throttle Position (TP) Sensor DH
Test
INote I
You should enter this Pinpoint Test only when a Service Code 23, 53, 63 or 73 Is
received during Quick Test.
IRemember I
may be at fault:
Idle speeds/throttle stop adjustment
Binding throttle shaft/linkage or speed control linkage
Choke/high cam system, if equipped
TP sensor may not be seated properly (tightened down)
Throttle Position (TP) sensor (-9B989-)
Sensor harness circuits: VREF, TP, and SIG RTN
Processor assembly (12A650)

ALL RIGHTS RESERVED
Pinpoint
Test

*TEST PIN 46 0~--SIG RTN - - - - - - - - ,
TEST PIN 47 0 TP ------._-----41+4

*TEST PIN 26 0 VREF-----+--~
TO 4EAT
MODULE FOR THROTTLE THROTTLE
1.9L MA AIT POSITION (TP) POSITION (TP)
AND 3.0L SENSOR SENSOR
PROBE AIT VEHICLE CONNECTOR
HARNESS
CONNECTOR
Sl~:;~
ALTERNATE THROTTLE
ALTERNATE THROTTLE
POSITION (TP) SENSOR.
POSITION (TP)
VEHICLE HARNESS
SENSOR
CONNECTOR
CONNECTOR
A13541-A

ALL RIGHTS RESERVED
Pinpoint
Test
Test Pin 46 SIG RTN

1.9L SEFI MA LG/BK
2.9L Scorpio BR
3.0L Probe LG/Y
All Others BK/W
Test Pin 26 VREF

1.9L SEFI MA 0"
R/W
2.9L Scorpio BR/BK
3.0L Probe LG/R
7.3L F-Series' Diesel
All Others O/W
Test Pin 47 TP
1.9L SEFI MA BR/W
2.9L Scorpio BR/BK
3.0L Probe LG/BK
All F-Series/Bronco GY/W
All Others DG/LG

ALL RIGHTS RESERVED
EEC-IV Pinpoint Test Procedures 17-79'
.Pinp~int
Throttle Position (TP) Sensor
Test
DH
NOTE: The normal range of the throttle angle measurement for the Throttle Position
(TP) sensor is from 0 to 85 degrees. To pass Quick Test, the throttle rotational
setting on the TP sensor (Key On Engine Off and Key On Engine Running), and
the maximum/minimum TP circuit operating voltage ranges are listed In T~ble # 1
by engine application.
TP Sensor Graph
SIGNAL
(volts)
4.538 -
4.257
3.648
3.039
2,429
1.820
1.210
0.601
o
26
I
I
I
THROTTLE SHAFT ROTATION
(DEGREES - TP ROTATIONAL ANGLE) I
84
A921O-B

ALL RIGHTS RESERVED
Pinpoint
Throttle Position, (TP) Sensor DH
Test
Table #1
Throttle Position Sensor Specifications
Throttle Position Sensor Setting TP Ctrcuit (Signal) Operating

(K.O.E.O. and K.O.E.R.) Voltage Range (K.O.E.O.)
Engine
Application I Rotational
Degree Range I .Voltage
Range
Minimum
I Maximum
Passenger Car:
1.9L EFI . 4 - 13 0.80 - 1.20 0.24 4.84

1.9L MA SEFI 3 - 13 0.70 - 1.20 0.20 4.84
0 - 12 (off) 0.49 - 1.15
1.9L CFI 0.39 4.84
2.5 - 14 (run) 0.71 - 1.25
2.3L OHC 0 - 13.5 0.59 - 1.22 0.20 4.84
2.3L HSC-EFI 3 - 13.5 0.73 - 1.22 0.20 4.84
1 - 15 (off) 0.66 - 1.30
2.5L HSC-CFI 0.39 4.84
3.5 - 25 (run) 0.76 - 1.78
3.0L EFI 0 - 13.5 0.59 - 1.22 0.34 4.84
3.0L SHO-MA SEFI 0 - 4.5 0.38 - 0.82 0.23 ' 4.89
3.8L FWD/RWD
3 - 13.5 0.73 - 1.22 0.39 4.84
3.8L/5.0L SEFI
3.8L SC MA
0 - 13.5 0.49 - 1.22 0.39 4.84
5.0L MA-SEFI
Truck:
2.3L DIS-EFI 0 - 13.5 0.59 - 1.22 0.34 4.84

2.9L EFI 0 - 13.5 0.59 - 1.22 0.34 4.84
3.0L EFI 0 - 13.5 0.59 - 1.22 0.34 4.84
4.0L EFI 0 - 13.5 0.59 - 1.22 0.34 4.84
4.9L EFI 3 - 13.5 0.73 - 1.22 0.20 4.84
5.0L EFI 3 - 13.5 0.73 - 1.22 0.20 4.84
5.8L EFI 3 - 13.5 0.73 - 1.22 0.20 4.84
7.5L EFI 3 - 13.5 0.73 - 1.22 0.20 4.84
5.8L/7.5L EFI E40D 3 - 13.5 0.73 - 1.22 0.34 4.84

ALL RIGHTS RESERVED
Pinpoint
Test
TEST STEP
. RESULT '~ ACTION TO TAKE
DH1 SERVICE CODE 23:

THE FOLLOWING CHECK MUST BE MADE
BEFORE SERVICING THIS CODE
. Service Code 23 indicates that the Throttle Position Yes ~ RETURN to the Key
(TP) sensor's rotational setting may be out of Self- On Engine Off or.
Test range (refer to Table # 1). Engine Running Service
Code chart and
Possible causes are: proceed as directed
with Codes 68, 31 or
- Binding throttle linkage. 58.
- TP sensor may not be seated properly
(tightened down). No ~ GO to IOH21.
- Faulty TP sensor.
- Faulty processor.
If you are in this Pinpoint Test Step for a Key,
On, Engine Off Code 23:
- Check for Code 68.
If you are in this Pinpoint Test Step for a Key
On, Engine Running Qode 23:
- Check for Codes 31 or 58.
Are any of the above codes present with
Code 23?
DH2 I CHECK FOR STUCK THROTTLE PLATE
Visually inspect carburetorIthrottle body and Yes ~ GO to IOH31.

throttle linkage for binding or sticking.
Verify the throttle linkage is at mechanical/closed No ~ SERVICE as necessary.
throttle. Check for: binding throttle linkage, speed RERUN Quick Test.
control linkage, vacuum linelelectrical harness
int~rference, etc.
Does throttle move freely and return to closed

throttle position?

ALL RIGHTS RESERVED
Pinpoint
Test

ATTEMPT TO GENERATE CODE 63
Service Code 53 indicates that the Throttle Position Yes ~ GO to IOH41.

(TP) sensor signal is greater than the Self-Test
maximum value (refer to Table # 1). No ~ GO to IOH61.
- TP sensor may not be seated properly
(tightened down).
- Faulty TP sensor.
- Short to power in harness.
- Faulty processor.
Disconnect TP sensor. Inspect for damaged or
pushed out pins, corrosion, loose wires, etc.
Disconnect both 4EAT module vehicle harness
connectors on 1.9L MA SEFI A/T and 3.0L Probe
A/T.
DH41 CHECK VREF CIRCUIT VOLTAGE
Key off, wait 10 seconds. Yes ~ For 1.9L MA SEFI

A/T and 3.0L Probe
TP sensor disconnected. A/T:
Both 4EAT module vehicle harness connectors GO to IOHSI.
disconnected (if applicable).
For all others:
DVOM on 20 volt scale. REPLACE TP sensor.
RERUN Quick Test.
Key on, engine off.
Measure voltage between VREF circuit and SIG No ~ RECONNECT TP
RTN circuit at the TP sensor vehicle harness sensor. GO to Pinpoint
connector. Test Step Ic11.

ALL RIGHTS RESERVED
.Pinpoint
Test
DH5 I CHECK FOR SHORTED 4EAT MODULE ..

NOTE: The 1.9L MA SEFI AfT and 3.0L Probe Yes ~ REPLACE TP sensor.
AfT vehicles have a TP circuit input to RERUN Quick Test.
the 4EAT module. This Test is to verify ",
that the TP circuit is not shorted insid~ No ~ GO to Transmissio'r,

the 4EAT module. Shop Manual Group to
~
check for short in

Key off. .4EAT system.
Reconnect TP sensor.
Both 4EAT module vehicle harness connectors
disconnected.
I~ code 53 present (ignore all other codes)? "
DH6 I CHECK TP CIRCUIT FOR SHORTS TO .POWER

TP sensor disconnected. RECONNECT tp
Disconnect processor 60 pin connector. Inspect ~ sensor. RERUN' Quick
-
I

components. RERUN

ALL RIGHTS RESERVED
Pinpoint
Test

ATTEMPT TO GENERATE CODE 53/23
Service Code 63 indicates that the Throttle Position Yes ~ REPLACE TP sensor.
(TP) sensor signal is less than the Self-Test REMOVE jumper.
minimum value (refer to Table # 1). RERUN Quick Test.

No ~ REMOVE jumper. GO
- TP sensor may not be seated properly to IDH111.
(tightened down).
- Faulty TP sensor.
- Open harness.
- Grounded harness.
- Faulty processor.
Disconnect TP sensor. Inspect for damaged or
Jumper VREF circuit to TP circuit at TP sensor
Perform Key On Engine Off Self-Test.
NOTE: If no codes are generated, immediately
remove jumper and go directly to IDH141,
except 1.9L MA SEFI A/T and 3.0L Probe
A/T, GO to IDH131.
Is Code 53/23 present (ignore all other
codes)?
DH111 CHECK VREF CIRCUIT VOLTAGE
Key off, wait 10 seconds. Yes ~ GO to IDH121.

Key 'on engin'e off.
connector.

ALL RIGHTS RESERVED
Pinpoint
Test
DH121 CHECK TP CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes .... GO to IDH141 .

TP ~ensor disconnected.
Disconnect processor 60 pin connector. Inspect No ~ SERVICE open circuit.
for damaged or pushed out pins, corrosion, loose REMOVE breakout box.
wires, etc. Service as necessary. RECONNECT all
components. RERUN
Install breakout box and connect processor to Quick Test.
breakout box.
DVOM , on 200 ohm scale.
Measure resistance between TP circuit at the TP
sensor vehicle harness connector and Test Pin 47
at the breakout box.
Is the resistance less than 5.0 ohms?
DH131 CHECK FOR SHORTED 4EAT MODULE
NOTE: The 1.9L MA SEFI A/T and 3.0L Probe Yes ~ DISCONNECT TP
A/T vehicles have a TP circuit input to sensor. GO to IDH141 .
the 4EAT module. This Test is to verify
that the TP circuit is not shorted inside
the 4EAT module.
No ~ GO to Transmission
Shop Manual Group to
Key off. check for short in
Reconnect TP sensor. 4EAT system.
Disconnect both 4EAT module vehicle harness
connectors.
I. Is code 63 present (ignore all other codes)?
,
OH141 CHECK TP CIRCUIT FOR SHORTS TO , ,
GROUND

TP sensor disconnected. REMOVE breakout box.
RECONNECT all
Both 4EAT module vehicle harness connectors components. RERUN
disconnected (if applicable). Quick Test.
for damaged or pushed out pins, corrosion, loose No ~ SERVICE short circuit.
components. RERUN

ALL RIGHTS RESERVED
1786 EEC~IV Pinpoint Test Procedures
Pinpoint
Throttle Position (TP) Sensor DM
Test
DH20 ENGINE RUNNING SERVICE CODE 73:

PERFORM PROPER DYNAMIC RESPONSE
TEST AT WIDE OPEN THROTILE
NOTE: Engine Running Service Code 73 indicates Yes ~ GO to IOH211.

the TP sensor did not exceed 25 percent
of its rotation during the Dynamic . No ~ Unable to duplicate
Response Test. A complete wide open Code 73 at this time.
throttle must be performed during the Go to Quick Test Step
Dynamic Response portion of the test. 5.0 to service other
.Engine Running Codes.
Run Key On Engine Running Self-Test. Be sure a Otherwise, testing
complete WOT is performed during the Dynamic completed.
Response portion of the test.
Is Code 73 still present?
DH21 CHECK TP SENSOR MOVEMENT DURING

DYNAMIC RESPONSE TEST

Disconnect processor 60 pin connector. Inspect RERUN Quick Test.
No ~ VERIFY TP sensor is
Install breakout box and connect processor to properly installed to
breakout box. throttle body. If OK,
REPLACE TP sensor.
DVOM on 20 volt scale. RERUN Quick Test.
Connect DVOM to Test Pin 47 and Test Pin 46
Rerun Engine' Running Self-Test with a proper
WOT Dynamic Response portion of the test.
Does voltage increase to greater than 3.5 volts
during the Dynamic Response Test?

ALL RIGHTS RESERVED
Pinpoint
Test
DH90 CONTINUOUS MEMORY CODE 53:

MONITOR TP CIRCUIT UNDER SIMULATED
ROAD SHOCK
Enter Key On Engine Off Continuous Monitor Yes ~ GO to IOH91 I.

mode. Refer to Quick Test Appendix.
Observe, VOM or STAR LED for indication of a No .~ GO to IOH921.
- Move throttle slowly ,to WOT position.
- Release throttle slowly to closed position and
lightly tap on TP sensor (simulate road
shock).
- Wiggle TP harness connector.
Does YOM or STAR LED indicate a fault?
POWER OR VREF
. CIRCUIT
/VREFO---X~";lt.
~TP SIG
SIG. RTN.
PROCESSOR HARNESS
<> ,. u'
/
)
TP SENSOR
A9468-A
DH91 MEASURE THROTILE POSITION SIGNAL

VOLTAGE WHILE EXERCISING TP SENSOR
Key off, wait 10 seconds. Yes ~ DISCONNECT and

Disconnect processor 60 pin connector. Inspect INSPECT connectors. If
for damaged or pushed out pins, corrosion, loose connector and
wires, etc. Service as necessary. terminals are good,
REPLACE TP sensor,
Install breakout box and connect processor to REFER to Fuel/Engine
breakout box. Shop Manual Group.
VOM or STAR LED still connected to STO as in CLEAR Continuous
previous step. Memory (REFER to
Connect a DVOM from Test Pin 47 to Test Pin RERUN Quick Test.
46 at the breakout box.
No ~ Throttle position sensor
Key on, engine off. overtravel may have
While observing DVOM, repeat Step IOH90 I. caused the Continuous
Memory Code 53.
Does the fault occur below 4.25 volts? VERIFY vehicle
harness integrity, GO
to IOH921.

ALL RIGHTS RESERVED
Pinpoint
Test
r
DH92 CHECK EEC-IV VEHICLE HARNESS
Still in Key On Engine Off Continuous Monitor Yes ~ ISOLATE fault.

REFER to appropriat.e
Observe YOM or STAR LED for a fault indication figure. CLEAR
while performing the following: Continuous Memory
- Referring to the illustration in Step IOH90 I, Appendix). RERUN
grasp the vehicle harness close to the sensor Quick Test.
connector. Wiggle, shake or bend a small
section of the EEC-IV system vehicle harness
while working your way to the dash panel. No ~ GO to IOH931.
Also wiggle, shake or bend the EEC-IV
processor.
DH931 CHECK PROCESSOR AND HARNESS

CONNECTORS

CLEAR Continuous
Disconnect processor 60 pin connector.' Inspect Memory (REFER to
for damaged or pushed out pins, corrosion, loose Quick Test Appendix).
wires, etc. Service as necessary. RERUN Quick Test.
Are connectors and terminals OK?
Yes ~ Unable to' duplicate
diagnosis using the
EEC-IV Monitor box,
REFER to Section 18
EEC-IV Monitor Box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.
-,

ALL RIGHTS RESERVED
EEC-IY Pinpoint Test Procedures 17-89
Pinpoint
Throttl~ Position (TP) Sensor DH
Test
DH94 CONTINUOUS MEMORY CODE 63:

MONITOR TP CIRCUIT UNDER SIMULATED <-
ROAD SHOCK
Enter Key On Engine Off Continuous Monitor Yes ~ INSPECT connectors. If

mode. Refer to Quick Test Appendix. connectors and
terminals are good,
Observe VOM or STAR LED for indication of a REPLACE TP sensor,
fault while performing. the following: REFER to Fuel/Engine
Shop Manual Group.
- Move throttle slowly to WOT position. CLEAR Continuous
- Release throttle slowly to closed position. Memory (REFER to
- Lightly tap on TP sensor (simulate road RERUN Quick Test.
shock).
- Wiggle TP harness connector. No ~ GO to IOH9SI.
TO GROUND
!~PVAEF~~
SIG~/
, ./)
III
,
SIG. RTN.tt /
PROCESSOR HARNESS TP ~NSOR
9592-8
.
DH95 CHECK EEC-IV VEHICLE HARNESS
Still in Key On Engine Off Continuous Monitor Yes .~ ISOLATE fault.

Observe VOM or STAR LED for a fault indication figure. CLEAR
- Referring to the illustration in Step IOH94 I Appendix). RERUN
section of the EEC-IV syst~m vehicle harness.
while working your way to the dash panel. No ~ GO to IOH961.
processor.

ALL RIGHTS RESERVED
. Pinpoin~
Test
DH961 CHECK PROCESSOR AND HARNESS

CONNECTORS

CLEAR Continuous
Disconnect processor 60 pin connector. Inspect Memory. REFER to
for damaged or pushed out pins, corrosion, loose Quick Test Appendix.
wires, etc. RERUN Quick. Test.
Are connectors and terminals OK?
Yes . Unable to duplicate
and/or identity fault at
diagnosis using the
EEC-IV Monitor box,
REFER to Section 18,
EEC-IV Monitor Box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.

ALL RIGHTS RESERVED
EECIV Pinpoint Test Procedure's 1791
Pinpoint
Engine RPM Sensor (Diesel) DJ
Test
INote I
You should enter this Pinpoint Test only when a Service Code 14 is received during
Quick Test or if you have been directed here from Diagnosis By Symptom.
IRemember I
To prevent the replacement of good components and spending needless time on diagnostics,
verify proper Engine RPM sensor installation and complete electrical connection.
Harness circuits: RPMS( +) and RPMS( - )
Engine RPM sensor (-178384-)
Processor assembly (-128565-)

-TEST PIN 44 @~ RPMS (-) -
TEST PIN 4 (!) RPMS ( + ) -------II----lI~
.~
ENGINE RPM SENSOR

VEHICLE HARNESS
* TEST PINS LOCATED ON BREAKOUT BOX. . CONNECTOR
All HARNESS CONNECTORS VIEWED INTO MATING SURFACE.
A 12796-B
Test Pin 44 RPMS( -) Test Pin 4 , RPMS(+)

Application Wire Color Application W!re Color
E-Series: BK/LG E-Series: DB
F-Series: DG F-Series: T/Y

ALL RIGHTS RESERVED
Pinpoint
Test
DJ1 ICONTINUOUS MEMORY CODE 14:

ERRATIC ENGINE RPM SIGNAL
NOTE: To prevent the replacement of good Yes ~ SERVICE as necessary.

components, verify proper Engine RPM CLEAR Continuous
sensor installation and complete electrical Memory (REFER to
connection. Quick Test Appendix).
RERUN Quick Test.
Service Code 14 indicates the Engine RPM signal
output was missing pulses while the engine was
running.
No ~ GO to IOJ21.
Check EEC-IV systems harness for:
- Loose wires/connectors.
- On board transmitter (2-way radio).
- On board telept1one, etc.
Verify installations have been performed according
to manufacturers instructions and specifications
regarding routing of antenna and wire leads. .
Enter Engine Running Continuous Monitor mode.
Refer to Quick Test Appendix.
- Lightly tap on the Engine RPM sensor. -
- Wiggle the Engine RPM sensor connector.
NOTE: Continuous Monitor mode may exit while
a fault is indicated. You have to reenter
to diagnose further.
DJ2 I CHECK, EEC-IV VEHICLE HARNESS
While still in Continuous Monitor mode from IOJ11 Yes ~ ISOLATE fault and
observe YOM or STAR LED for a fault indication SERVICE as necessary.
while ,performing the following: CLEAR Continuous
Memory (REFER to
- Grasp the vehicle harness close to the Quick Test Appendix).
Engine RPM sensor. Wiggle shake or bend a RERUN Quick Test.
small section at a time while working your
way toward the dash panel and the EEC-IV
processor. Isolate the Engine RPM circuit for
No ~ GO to IOJ31.
this test.

ALL RIGHTS RESERVED
.Pinpoint
Test
. - .
DJ3 CHECK CONTINUITY OF ENGINE RPM

SENSOR VEHICLE HARNESS CIRCUITS
Key off, wait 10 seconds. Yes ~ GO to IOJ41.

components. RERUN
Disconnect Engine RPM sensor. Quick Test.
breakout box and RPMS( +) circuit at the Engine
RPM sensor vehicle harness connector.
breakout box and RPMS( -) circuit at the Engine
RPM sensor vehicle harness connector.
-
DJ4 CHECK ENGINE RPM SENSOR VEHICLE
HARNESS CIRCUITS FOR SHORTS TO POWER
OR GROUND
Key off. Yes ~ GO t.o IOJ51.

Engine RPM sensor disconnected. No ~ SERVICE short circuit.
Measure resistance between Test Pin 4 and Test .. components. RERUN
Pins 37/57, 40, and 44 at the breakout box. Quick Test.
Pins 37/57 at the breakout box.
DJ5 CHECK ENGINE RPM SENSOR RESISTANCE

.- -
Engine RPM sensor di.sconnected. REMOVE breakout box.
RECONNECT Engine
DVOM on 200,000 ohm scale.. RPM sensor. RERUN
Measure resistance between Engine RPM sensor Quick Test.
terminals at the RPM sensor. .
Is the resistance between 2,400 and 2,800 No ~ REMOVE breakout box.
ohms? RECONNECT all
components. GO to
InstrumentslGauge
Shop Manual Group.

ALL RIGHTS RESERVED
Pinpoint
Vane Air Flow (VAF) Sensor DK
Test
INote I
You should enter this Pinpoint Test only when a Service Code 26, 56, 66 or 76 Is
received during Quick Test.
IRemember I
may be at fault:
Check for unmetered air (air leaks) between VAF meter and throttle body
Vacuum leaks
Engine sealing (PCV sealing, CANP, valve cover seal, dipstick seated)
Vane Air Flow (VAF) meter (-128529-)
Harness circuits: VREF, VAF, and SIG RTN

"TEST PIN 25 @- LG/P - - VAT-~~ ......+ - - - - - - V A T
TEST PIN 43 Gr-W/BK -VAF--t-+"'""ftt cu....t - - - - - - V A F
TEST PIN 26 (irOIW - - VREF ---tt--tH CUHt--t-----VREF
TEST PIN 46 (!)-BKIW - SIG RTN --.--.-~-. HI-+-----SIG RTN
BLANK
VAFMETER
VANE AIR FLOW (VAF) CONNECTOR
METER VEHICLE
HARNESS CONNECTOR

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A9593E

ALL RIGHTS RESERVED
Pinpoi.Dt
Test
NOTE: Air flow = Volume of air flowing through VAF meter per hour
As the volume of air flowing through the VAF meter increases, so will
the VAF sensor output voltage.
Vane Air Flow Sensor Graph
1.9L EFI Engine
VAF SENSOR OUTPUT (volts)
5.0
4.5
4.0
3.5
3.0.
2.5
2.0
1.5
0.5
50 100 150 200 . 250 300 350 400
AIR FLOW (m1hr)

A8907B
VAF Sensor Data
Air Flow VAF Sensor Output

3
m /hr Volt
9 0.80
16 1 1.35
26 1.85
40 2.25
60 2.65
100 3.15
160 3.60
240 4.0
380 4.5

ALL RIGHTS RESERVED
IVane Air Flow (VAF) Sensor Pinpoint

Test
DK
DK1 SERVICE CODE 26:

CHECK VAF METER FOR CONTAMINATION
AND FREEDOM OF MOVEMENT
Service Code 26 indicates that the Vane Air Flow Yes ~ If you are originally
(VAF) sensor is out of Self-Test range. Correct here for a KOEO
range of measurement is 0.17 to 0.50 volts (KOEO) Service Code 26:
or 1.10 to 1.70 volts (KOER). REFER to Section 3,
Vane Air Flow Meter
Possible causes: Diagnosis.
- Faulty VAF meter. If you are originally
here for an Engine
- Faulty processor.
Running Service Code
- Faulty wire harness connections. 26:
GO to IOK21.
Rem,ove air cleaner element and check VAF No ~ If you are originally
meter for contamination (oil residue, foreign here for a KOEO
material, etc.) that may impede VAF sensor vane Service Code 26:
movement. GO to IOK21.
Rerun Quick Test. If you are originally
Is Service Code 26 present? here for an Engine
Running Service Code
26:
Testing is complete.

ALL RIGHTS RESERVED
Pinpoint
IVane Air Flow (VAF) Sensor Test
DK
DK2 CHECK VAF SENSOR
Key off.. Yes ~ VAF meter is capable

.of outputting an
Check for unmetered air leaks between VAF acceptable signal. The
meter and throttle body. Code 26 has been
caused by incorrect
engine speed or an
for damaged or pushed out pins, corrosion, loose unmetered air leak
wires, etc. Service as necessary. (vacuum leak). 1.9L
Install breakout box and connect processor to EFI, GO to IKD 151.
breakout box. . All others, SERVICE as
necessary. REMOVE
Place new unsharpened pencil as shown belo~. breakout box. RERUN
Quick Test.
Key on, engine off. No ~ INSPECT VAF meter
connectors for bent
Measure voltage between Test Pins 43 and 46 at
pins. SERVICE as
the breakout box. necessary. REMOVE
Is Yoltage between 2.8 Yolts and 3.7 YOIts? breakout box.
RECONNECT
processor. RERUN
Quick Test. REPLACE
VAF meter if problem
still exists.
VAF.METER VAF SENSOR AIR VANE
AIRFLOW
NOTE: REFER TO COVER PAGE FOR HARNESS CONNECTOR PIN ASSIGNMENTS. A9594E

ALL RIGHTS RESERVED
Pinpoint
Test

INDUCE OPPOSITE CODE
Service Code 56 indicates that the Vane Air Flow Yes ~ GO to IOK111.
(VAF) sensor signal is greater than the Self-Test
maximum value of 4.89 volts (KOEO).
No ~ GO to IOK121.
Possible causes:
- Faulty VAF meter.
- Faulty processor.
- VAF circuit shorted to power; faulty wire
harness.
Disconnect VAF meter. Inspect for damaged or
Rerun Key On, Engine Off Self-Test.
Is Code 66 present?
DK111 CHECK VREF CIRCUIT VOLTAGE
Key off, wait 1 seconds. Yes ~ REPLACE VAF meter.

RERUN Quick Test.
VAF meter disconnected.
No ~ GO to Pinpoint Test 4
Key on, engine off. Step IC11.

RTN circuit at the VAF meter vehicle harness
connector.
Is Yoltage between 4.0 and 6.0 Yolts?
DK121 CHECK VAF CIRCUIT FOR SHORT TO POWER

RECONNECT VAF
Disconnect processor 60 pin connector. Inspect meter. RERUN Quick
No
SERVICE circuit shorts.
RECONNECT all
components. RERUN
Pins 26 and 57 at the breakout box. Quick Test.

ALL RIGHTS RESERVED
Pinpoint
DK
I
INDUCE OPPOSITE CODE
Service Code 66 indicates that the Vane Air Flow Yes ~ REPLACE VAF meter.
(VAF) serisor signal is less than the Self-Test . REMOVE jumper wire.
minimum. of 0.17 volts (KOEO). RERUN Quick Test.
Possible causes:
No .~ REMOVE jumper wire.
- Faulty VAF meter. and GO to IOK211.
- Lack of continuity between VAF meter vehicle

harness connector and processor.
- VAF circuit shorted to ground.
- Faulty processor.
Key -off, wait 10 seconds.
Disconnect VAF meter.
Install jumper wire in VAF meter vehicle harness
connector between VREF circuit and VAF circuit.
Perform Key On, Engine Off Self-Test.
NOTE: If no codes are generated, immediately
remove jumper and go directly to IOK23 I.
Is Code 56 present?
I
DK21 CHECK VREF CIRCUIT VOLTAGE
Key off, wait 10 seconds. Yes ~ GO to IOK221.

Key on, engine off.
RTN circuit at the VAF meter vehicle harness
connector.
.

ALL RIGHTS RESERVED
17100 EEC-IVPlnpolnt Test Procedures
Pinpoint
Test
TEST STEP RESULT 'ACTION TO TAKE
DK221 CHECK VAF CIRCUIT CONTINUITY
Key off. Yes ~ GO to IOK231.

Quick Test.
Measure resistance between VAF circuit at the
VAF meter vehicle harness connector and Test
DK231 CHECK VAF CIRCUIT FOR SHORT TO

, GROUND
Key off, wait 10 seconds. Yes REPLACE processor.

Breakout box installed, processor disconnected. RECONNECT VAF
VAF meter disconnected. meter. RERUN Quick
Test.
Measure resistance between VAF circuit and SIG No ~ SERVICE short circuit.
RTN circuit at the VAF meter vehicle harness REMOVE breakout box.
connector. RECONNECT all
components. RERUN
Measure resistance between VAF circuit at the Quick Test.
VAF meter vehicle harness connector and battery
negative post.
*TESTPIN25 0--VAT-----+=~~~'-,...n :
. TESTPIN43 - - V A F - - -.......J........~l,cD
TEST PIN 26 0--VREF--~IoP.,~~r:;n
TEST PIN 46 (V--SIG RTN -~~~~~'~n,
--BLANK
~
--
VANE METER VEHICLE
HARNESS CONNECTOR
A8909B

ALL RIGHTS RESERVED
Pinpoint
Vane' Air Flow (VAF) Sensor DK
Test

CHECK FOR VOLTAGE INCREASE IN VAF
SIGNAL DURING DYNAMIC RESPONSE
, .
Service Code 76 indicates that the VAF output Yes ~ GO to IDK31 I.

voltage did not change enough during the Dynamic
Response Test. No ~ CHECK air c1~aner
duct for obstruction. If
Possible causes:
OK, REPLACE VAF
- Air cleaner duct obstruction. meter.
- Faulty VAF meter.
- Faulty processor.
Install breakout box and connect processor to'
breakout box.
.
Connect DVOM to Test Pins 43 and 46 at the
breakout box.
Perform Engine Running Quick Test while
monitoring DVOM.
~
After dynamic response prompt Code 1(0)

operator moves throttle briefly to WOT and back.
DVOM should increase more than 2.0 volts from
reading before WOT.
Record service codes at end of test.
Did Yoltage increase more than 2.0 YOIts?
DK31 CHECK SERVICE CODES FROM STEP DK 30

..
Check Engine Running service codes recorded in Yes ~ REPLACE processor.
Pinpoint Test Step IDK30 I. - REMOVE -breakout box.
RERUN Quick Test.
Is Code 76 present?
No ~ VAF meter is OK,
SERVICE other codes
as necessary.

ALL RIGHTS RESERVED

Test
DK
1
DK901 CONTINUOUS MEMORY CODE 56:

CHECK VAF SENSOR
Continuous Memory Code 56 indicates that the Yes ~ DISCONNECT and

Vane Air Flow (VAF) sensor signal was greater than INSPECT connectors. If
the Self-Test maximum value of 4.89 volts. The connector and
code was set during normal driving conditions. terminals are good,
REPLACE VAF sensor.
Possible causes: CLEAR Continuous
Memory (REFER to
- Faulty VAF meter. Quick Test Appendix).
- Faulty VAF meter vehicle harness connectors RERUN Quick Test.
and/or terminals.
No ~ GO to IDK91! .
- Faulty processor vehicle harness connector
and/or terminals.
- Lightly tap on VAF sensor (simulate road
shock).
- Wiggle VAF vehicle harness connector.
VREF
i ,'t:\
@PROCESSOR
>--VAF
LSIGRTN~
* (~
I
VAF SENSOR
HARNESS
A9595-C

ALL RIGHTS RESERVED

Test
DK
I
DK91 CHECK EEC-IV VEHICLE HARNESS
Still in Key On, Engine Off Continuous Monitor Yes ~ ISOLATE fault and
- Referring to the illustration in Step IOK90 I, Appendix). RERUN
grasp the harness close to the sensor Quick Test.
connector. Wiggle, 'shake or bend a small
while working your way to the dash panel. No ~ GO to IOK921.
processor.
DK921 CHECK PROCESSOR AND VEHICLE HARNESS

CONNECTORS
Key off, wait 10 seconds. Yes ~ Unable to duplicate

Disconnect processor 60 pin connector. Inspect this time. For further
both connectors and connector terminals for diagnosis using the
obvious damage or faults. EEC-IV Monitor box,
REFER to Section 18
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.
CLEAR Continuous
Memory (REFER to
RERUN Quick Test.

ALL RIGHTS RESERVED
Pinpoint
DK
DK931 CONTINUOUS MEMORY CODE 66:

CHECK VAF SENSOR
Continuous Memory Code 66 indicates that the Yes ~ REPLACE sensor.

Vane Air Flow (VAF) sensor signal was less than DISCONNECT and
the Self-Test minimum of 0.17 volts. The code was INSPECT connectors. If
set during normal driving conditions. connector and
terminals are good,
Possible causes: CLEAR Continuous
Memory (REFER to
- Faulty VAF meter vehicle harness. Quick Test Appendix).
- Faulty VAF meter. RERUN Quick Test.
- Faulty processor assembly.

No ~ GO to IOK941.
- Lightly tap on VAF sensor (simulate road
shock).
- Wiggle VAF vehicle harness connector.

/VREF~
, ~
r-.VAF--o..
,~
)~ ~
SIGRTN .." /
PROCESSOR HARNESS VAF SENSOR
A9469B

ALL RIGHTS RESERVED
Pinpoint
Test
DK941 CHECK EEC-IV VEHICLE HARNESS
Still in Key On, Engine Off Continuous Monitor Yes ~ ISOLATE fault and
Observe VOM or STAR LED for a fault ir)dication figure. CLEAR
- Referring to the illustration in Step IDK93 I, Appendix). RERUN
while working your way to the dash panel. No ~ GO to IDK9S1 .
processor.
DK951 CHECK PROCESSOR AND VEHICLE HARNESS

CONNECTORS
Key off, wait 10 seconds. No ~ SERVICE as 'necessary.

CLEAR Continuous
Disconnect processor 60 pin connector. Memory (REFER to
Inspect both connectors and connector terminals Quick Test Appendix).
RERUN Quick Test.
Are connectors and terminals OK? Yes ~ Unable to duplicate
diagnosis using the
EEC-IV Monitor box,
REFER to Section 18
EEC-IV Monitor Box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.

ALL RIGHTS RESERVED
Pinpoint
Test
DK9S1 CONTINUOUS MEMORY CODE 26:
Continuous Memory Code 26 indicates that Yes ~ REPLACE VAF meter.

sometime during vehicle operation, the VAF signal RERUN Quick Test.
was out of Self-Test range.
RERUN Quick Test.
- Contamination.
- Unmetered air leaks.
- Faulty VAF meter.
Key off.
Inspect integrity of VAF meter and associated air
tubes.
Check for unmetered air leaks.
Remove air cleaner element and check for
contamination (oil residue, foreign material, etc.)
that may impede VAF sensor vane movement.
Are all the above checks OK?

ALL RIGHTS RESERVED
Pressure Feedback EGR (PFE) Pinpoint

DL
EGR Vacuum Regulator (EVR) Test
INote I
You should enter this Pinpoint Test only when a Service Code 31, 32, 33, 34, 35 or 84
is received during Quick Test.
IRemember I
may be at fault:
Damaged EGA valve.
Restricted exhaust system
Damaged vacuum reservoir or canister
This Pinpoint Test is intended to diagnose only' the following:
Harness circuits: VAEF, PFE, SIG ATN, EVA, VPWA.
PFE sensor (-90460-)
EVA solenoid (-9J459-)
EGA valve assembly
Vacuum lines/tubes (EVA, PFE)

ALL RIGHTS RESERVED
Pressure Feedbac" EGR (PFE) Pinpoint

DL
EGR Vacuum Regulator (EVR) . Test

PFE SENSOR
*TEST PIN 27 ~ PFE VEHICLE
TEST PIN 46 . SIG RTN HARNESS
TEST PIN 26 VREF------~MlC:J.1II CONNECTOR
(TEST PIN 52, 1.9L CFI) t:'\ DG EVR ~ EVR SOLENOID

TEST PIN 33 \ ! . I ' - - - - - - - - ----
VEHICLE
HARNESS
*TEST PIN 37 ~VPWR CONNECTOR
e-----J
TEST PIN 57


ALL RIGHTS RESERVED
Pressure' Feedback EGR (PFE) Pinpoint

DL
Test Pin 33 (52) EVR Test Pin 26 VREF

Application Wire Color Application Wire Colors
1.9L MA SEFI W/BL 1.9L MA SEFI R/W
1.9L CFI 2.9L Scorpio BR/BK
2.3L HSC EFI Y
3.0L EFI Probe LG/R
2.3L OHC MA
4.9L E-Series/Bronco
2.5L FLC CFI
3.0L SHO SEFI
3.0L EFI DG
3.8L AXOD SEFI
7.5L F-Series
3.8L RWD SEFI
All Others O/W
3.0L EFI Probe W
2.3L EFI MA, Truck
5.0L EFI, E-Series DG
Test Pin 27 PFE
Application Wire Colors
5.0L EFI, F-Series/Bronco BR/PK
1.9L MA SEFI BL/Y
Test Pin 46 SIG RTN All Others BR/LG
1.9L MA SEFI LG/B
2.9L Scorpio ~BR
3.0L EFI Probe LG/Y
4.9L E-Series/Bronco
7.5L F-Series
All Others BK/W

ALL RIGHTS RESERVED

DL
NOTE: Voltage values calculated for VREF =

5.0 volts. These values may vary 15
percent due to sensor and VREF variations.
PFE Sensor Graph
PRESSURE (kPa)
15
10
5
o
-5
-10
-15
-20
-25 ...........-::;;;;.....&.....-_+-_ _L.-_---f_ _.--Io_ _-+-_ _..Io-_ _+-__....._ - - t
Ov 1v 2v 3v 4v 5v
Voltage Reldlng (volta)

A891OB
PFE Sensor Data
Pressure/Vacuum
PSI in-Hg kPa Voltage
1.82 3.70 12.5 4.75
1.36 2.79 9.42 4.38
0.91 1.85 6.25 4.0
0.46 0.94 3.17 3.63
0 0 0 3.25
-2.47 -5.03 -17.0 1.22
-3.63 -7.40 -25.0 0.25
CAUTION: To avoid possible sensor damage
do not exceed pressure/vacuum
range shown when testing.

ALL RIGHTS RESERVED

DL
DL1 ISERVICE CODE 31:

INDUCE CODE 35
Service Code 31 indicates that the Pressure Yes ~ REPLACE PFE sensor.
Feedback EGR (PFE) sensor signal is less than the REMOVE Jumper.
Self-Test minimum value of 0.2 volts. RERUN Quick Test.
- Faulty PFE sensor.
No ~ REM01E iUiper.
GO to OL2 .
- Open harness. circuits.
- Shorted harness circuits.
- Faulty processor.
Key off.
Disconnect PFE sensor.
Jumper VREF circuit to PFE circuit at PFE sensor
Perform Key On, Engine Off Self-Test.
NOTE: If no codes are generated, Immediately
remove jumper and go directly to. Step
IOL41. .
DL2 I MEASURE VREF CIRCUIT VOLTAGE
Key off. Yes ~ GO to IOL31.

PFE sensor disconnected.
Step IC11.
Key on, engine off.
RTN circuit at the PFE sensor vehicle harness
connector.
Is voltage between 4 and 6 volts?
DL3 I CHECK PFE CIRCUIT CONTINUITY
Key off. Yes ~ SERVICE open circuit.

PFE sensor disconnected. RECONNECT all
Disconnect processor 60 pin connector. Inspect components. RERUN
Install breakout box, leave processor disconnected. No ~ GO to IOL41.
Measure resistance between PFE circuit at the
PFE sensor vehicle harness connector and Test
Is resistance greater than 5 ohms?

ALL RIGHTS RESERVED

DL
DL41 CHECK PFE CIRCUIT FOR SHORTS

TO GROUND AND SIG RTN

PFE sensor disconnected. RECONNECT all
Quick Test.
Measure resistance between PFE circuit at the No ~ SERVICE short circuit.
PFE sensor vehicle harness connector and Test REMOVE breakout box.
Pins 40 and 60 at the breakout box. RECONNECT all
components. RERUN
Measure resistance between PFE circuit at the Quick Test.
PFE sensor vehicle harness connector and Test
DLSI SERVICE CODE 35:

INDUCE CODE 31
Service Code 35 indicates that the Pressure Yes ~ GO to IOL61.

Feedback EGR (PFE) sensor signal is greater than
the Self-Test maximum value of 4.8 volts. No ~ GO to IOL71.
- Shorted harness circuits.
- Faulty processor.
Key off.
Rerun Key On, Engine Off Self-Test.
DL6 I MEASURE VREF CIRCUIT VOLTAGE
Key off. Yes ~ REPLACE PFE sensor.

RERUN Quick Test.
PFE sensor disconnected.
DVOM on 20 volt scale. No ~ GO to Pinpoint Test
Step ~.
Key on, engine off.
RTN circuit at the PFE sensor vehicle harness
connector.

ALL RIGHTS RESERVED

DL
OL71 CHECK PFE CIRCUIT FOR SHORTS TO

POWER

PFE sensor disconnected. RECONNECT PFE
Install breakout box, leave processor disconnected. No ~ SERVICE short circuit.
Measure the resistance between Test Pin 27 and components. RERUN
Test Pins 26, 37 and 57 at the breakout box. Quick Test.
OL81 SERVICE CODE 34:

VERIFY ENGINE RUNNING CODES
Service Code 34 indicates that the Pressure Yes ~ GO to IDL91.

Feedback EGR (PFE) sensor is out of Self-Test
range and that the PFE sensor is probably
defective. Correct range of measurement is 2.6 to
No ~ ADDRESS other codes
in Key On Engine Off.
4.2 volts. If none, CONTINUE
Possible causes are: with remaining Quick
Test.
- Obstructed pressure feed tube.
- Garage exhaust ventilation system affecting PFE
sensor operation.
NOTE: PFE system can sense a lack of pressure
in the vehicle exhaust system. An
efficient garage exhaust ventilation
system that is Installed during Key On
Engine Off SelfTest may generate a
Code 34.
Remove garage forced ventilation system and
properly vent to atmosphere.
Is Code 34 present?
OL9 I CHECK PFE SENSOR PRESSURE INPUT HOSE
Remove the pressure input hose from PFE Yes ~ SERVICE as necessary.
sensor. RERUN Quick Test.
Inspect complete tube and PFE sensor inlet for
blockage. No ~ RECONNECT pressure
Is blockage present? tnput rose. GO to
DL10 .

ALL RIGHTS RESERVED

DL
I
DL10 MEASURE VREF CIRCUIT VOLTAGE
Key off. Yes ~ REPLACE PFE sensor.

RERUN Quick Test.
Step IC11.
Key on, engine off.
RTN circuit at PFE sensor vehicle harness
connector.
DL11/ SERVICE CODE 84:

MEASURE EVR SOLENOID RESISTANCE
Service Code 84 indicates a failure in the EGR Yes ~ . GO to IOL121.

Vacuum Regulator (EVR) solenoid or circuit.
Possible causes are: No ~ REPLACE EVR
solenoid. RERUN Quick
- Faulty EVR solenoid. Test.
- Open harness circuit.
- Shorted harness.
- Faulty processor.
Key off.
Disconnect EVR solenoid.
Measure EVR solenoid resistance.
Is solenoid resistance between 30 and 70
ohms?
DL121 CHECK VPWR CIRCUIT VOLTAGE
Key on, engine off. Yes ~ SERVICE open circuit.

RERUN Quick Test.
EVR solenoid disconnected.
DVOM on 20 volt scale. No ~ GO to IOL131.
Measure voltage between battery negative terminal
and VPWR circuit at EVR solenoid vehicle
harness connector.

ALL RIGHTS RESERVED

DL
TEST ~TEP RESULT ~ ACTION TO TAKE
Ill13 1 CHECK EVR CIRCUIT CONTINUITY
Key off. 'Yes ~ GO to IOL141.

wires, etc. Service as necessary. component~. RERUN
Quick Test.
Measure resistance between Test Pin 33 (Test Pin
52, 1.9L CFI) at the breakout box and EVR circuit
at the EVR solenoid vehicle harness connector.
Dl141 CHECK EVR CIRCUIT FOR SHORTS TO

POWER OR GROUND

EVR solenoid disconnected. RECONNECT aIJ
Quick Test.
Measure resistance between Test Pin 33 (Test Pin No ~ SERVICE short circuit.
52, 1.9L CFI) and Test Pins 37 and 57 at the REMOVE breakout box.
breakout box. RECONNECT all
components. RERUN
Measure resistance betwee~ Test Pin 33 (Test Pin Quick Test. If code is
52, 1.9L CFI) and Test Pins 40 and 60 at the repeated, REPLACE
breakout box. processor.
..

ALL RIGHTS RESERVED

DL
DL20 SERVICE CODE 32:

VERIFY ENGINE RUNNING CODES
Service Code 32 indicates that the EGR valve is Yes ~ GO to IDL211 .

not fully seated.
Possible causes are: No ~ ADDRESS other codes
in Engine Running. If
- Obstructed vacuum hose.
none, CONTINUE with
- Contaminated EVR filter. remaining Self-Test.
- Faulty EGR valve.
- Faulty EVR solenoid.
- Garage exhaust ventilation system.
NOTE: PFE system can sense a lack of pressure
in the vehicle exhaust system. An
efficient, garage exhaust ventilation
system that is installed during Key On
Engine Running SelfTest may generate a
Code 32.
Remove garage forced ventilation system and
properly vent to atmosphere.
Is Code 32 present?

RERUN SELF-TEST WITH EGR VALVE
VACUUM LINE DISCONNECTED
Service Code 31 indicates that the Pressure Yes ~ GO to IDL22 I.

Feedback EGR (PFE) sensor signal is less than the
Self-Test minimum of 3.25 volts.
No ~ EVR filter or solenoid
Key off. is contaminated.
Disconnect EGR valve vacuum line at valve and REPLACE EVR
plug vacuum line. solenoid. RECONNECT
all lines. RERUN Quick
Perform Engine Running Self-Test. Test.
Is Code 31 or 32 present?
DL22 CHECK PFE SENSOR PRESSURE INPUT HOSE

FOR BLOCKAGE
Key off. Yes ~ SERVICE as necessary.

Check PFE sensor pressure input hose for RECONNECT all lines
obstructions and/or leaks. and RERUN Quick
Test.
.Are there any obstructions or leaks?
No ~ GO to EGR Diagnosis,
Section 6.

ALL RIGHTS RESERVED

DL
EGR Vacuum Regulator (EVR) . Test
"
DL25 SERVICE CODE 34 AND 35:

CHECK FOR EXCESSIVE EXHAUST BACK
PRESSURE
Service Codes 34 and 35 indicates that there is Yes ~ REINSTALL original

excessive exhaust back pressure. PFE sensor. GO to
Section 5, Catalyst and
Possible causes are: Exhaust Systems.
- Restricted exhaust system.
No ~ Original PFE sensor
was the cause of the
Key off. Service Code 34 or 35.
REPLACE PFE sensor.
Substitute known good PFE sensor in place of RERUN Quick Test.
original.
Re,run Engine Running Self-Test.

VERIFY VACUUM IS PRESENT AT EGR VALVE
Service Code 33 indicates that the PFE sensor Yes ~ REMOVE vacuum
input did not change after the EVR solenoid was gauge. GO to IDL31 I.
instructed by the processor to open the EGR valve.
Possible causes are: No ~ REMOVE vacuum
gauge. GO to IDL36 I.
- Vacuum hose leaks.
- Obstructed vacuum hose. -
- Faulty EVR solenoid.
- Faulty EGR valve.
- Faulty PCV valve (1.9L CFI only).
. Tee in a standard vacuum gauge at the EGR
valve.
Rerun Engine Running Self-Test while observing
vacuum gauge.
Is vacuum reading less' than 1 in-Hg
throughout the test (disregard code output)?

ALL RIGHTS RESERVED

DL
DL31 I CHECK VACUUM HOSES
Key off. Yes ~ For 1.9L CFI:

GO to IOL321.
Check the following vacuum hoses for
obstructions, cracks or loose connections: For all others:
GO to IOL341.
- EVR solenoid to EGR" valve.
- EVR solenoid to source. No ~ SERVICE as necessary.
- EVR solenoid to PCV valve (1.9L CFI only). RERUN Quick Test.
Are vacuum hoses in good condition?
I
DL32 CHECK SOURCE LINE VACUUM
Key off, wait 10 seconds. Yes ~ GO to IOL3S1 .

Attach vacuum gauge to source line between
throttle body and EVR solenoid at the EVR No ~ GO to IOL33 I.
solenoid.
Start engine.
Run engine at approximately 2000 rpm.
Is vacuum reading greater than 10 in-Hg?
I
DL33 CHECK PCV VALVE OPERATION
Key off. .. Yes ~ REMOVE vacuum

gauge. RECONNECT
Disconnect vacuum hose at the PCV valve from PCV valve. REPLACE
the EVR solenoid. vacuum line to EGR
Connect a vacuum pump to the PCV valve. solenoid from throttle
body.
Slowly apply 10 in-Hg vacuum.
Does the PCV valve open and maintain No ~ GO to Section 9 for
vacuum? PCV valve diagnosis.
I
DL34 CHECK VACUUM TO EVR SOLENOID
Key off, wait 10 seconds. Yes ~ GO to IOL3sl.

Attach vacuum gauge to source line from
manifold. No ~ REPLACE vacuum line
to EVR solenoid.
Start engine and run at idle. RERUN Quick Test.
Is vacuum present?

ALL RIGHTS RESERVED

DL
I
DL35 CHECK EGR VALVE OPERATION
Key off. Yes ~ REPLACE EVR

solenoid assembly.
Disconnect vacuum hose at the EGR valve. REMOVE vacuum
Connect a vacuum pump to the EGR valve. pump. RECONNECT
EGR valve. RERUN
While observing the EGR valve, slowly apply 10 Quick Test.
in-Hg vacuum.
NOTE: EGR valve should begin to open with a No ~ GO to Section 6 for
very small amount of vacuum, EGR valve diagnosis.
approximately 1 to 1.5 in-Hg and be fully
open with about 4 in-Hg vacuum.
Does the EGR valve move freely and
smoothly?
I
DL36 CHECK PFE SENSOR CONTROL PRESSURE
INPUT TUBE

RERUN Quick Test.
Is control pressure input tube to PFE sensor
cracked, disconnected or obstructed?
No ~ GO to IOL371.

ALL RIGHTS RESERVED
17-120 EEC-IV Pinpoint Test Procedu~s

DL
I
OL37 SUBSTITUTE KNOWN GOOD PFE SENSOR
Key off, wait 10 seconds. Yes ~ REINSTALL original

PFE sensor. GO to
Substitute known good PFE sensor in place of
Section 6 for EGR
original.
valve diagnosis.
Is Code 33 present? No ~ Original PFE sensor
was the cause of the
Service Code 33.
REPLACE PFE sensor.
RERUN Quick Test.
I
OL90 CONTINUOUS MEMORY CODE 31 OR 35:
EXERCISE PFE SENSOR
Continuous Memory Codes 31 and 35 indicate that Yes ~ DISCONNECT and

the Pressure Feedback EGR (PFE) sensor signal INSPECT connectors. If
went either less than (Code 31) or greater than connector and
(Code 35) the Self-Test voltage sometime during terminals are good,
vehicle operation. REPLACE PFE sensor.
Possible causes are: CLEAR Continuous
Memory (REFER to
- Damaged connectors and/or terminals. Quick Test Appendix).
- Open or grounded harness. RERUN Quick Test.
No ~ GO to IDL91 I.
Connect a vacuum pump to the PFE sensor.
Slowly apply 5 in-Hg to the PFE sensor.
Slowly bleed vacuum off the PFE sensor.
Lightly tap on PFE sensor (to simulate road
shock).
Wiggle PFE sensor vehicle harness connector.
Is fault Indicated?
~/VAEF~~
,
,>--PFE-O
~ L/.
SIG. RTN.
N' If) ,
A9597-B

ALL RIGHTS RESERVED
EEC-IV Pinpoi~t Test Procedures 17-121 ,

DL
I
DL91 CHECK EEC-IV VEHICLE HARNESS
Still in Key On Engine Off Continuous Monitor Yes ~ ISOLATE fault and
CLEAR Continuous
Observe YOM or STAR LED for a fault indication Memory (REFER to
while performing the following: Quick Test Appendix).
RERUN Quick Test.
- Referring to the illustration in Step IOL90 I
grasp the vehicle harness closest to the
sensor connector. Wiggle, shake or bend a No ~ GO 'to IOL921.
small section of the EEC-IV system vehicle
panel. Also wiggle, shake or bend the EEC-IV
processor.
I
DL92 CHECK PROCESSOR AND VEHICLE HARNESS
CONNECTORS

Inspect both connectors and connector terminals diagnosis using the
EEC-IV Monitor box,
REFER to Section 18
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.
No ~ SERVICE as necessary,
CLEAR Continuous
Memory (REFER to
RERUN Quick Test.

ALL RIGHTS RESERVED
, 17-122 EEC-IV Pinpoint Test Procedures

DL
EGR Vacuum Regulator (EVR) .Test
OL931 CONTINUOUS MEMORY CODE 34:

- INSPECT PFE SUPPLY TUBE FOR BLOCKAGE
Continuous Memory Code 34 indicates that at Yes ~ Unable to duplicate

sometime during vehicle operation, the PFE sensor and/or identity fault at
experienced a restriction. this time. For further
diagnosis using the
Key off. EEC-IV Monitor box,
REFER to Section 18
Remove PFE sen~or and inspect sensor supply EEC-IV Monitor Box:
inlet for liquids and/or any type of blockage. Intermittent Fault
Inspect PFE supply tube to EGR valve base for Diagnosis.
liquids and/or blockage.
All others, CLEAR
Is supply tube free of any blockage? Continuous Memory
Appendix). RERUN
Quick Test.
No ~ CLEAN and/or
SERVICE as necessary.
CLEAR Continuous
Memory (REFER to
RERUN Quick Test.
I
DL94 CONTINUOUS MEMORY CODE 32:
CHECK EGR VALVE OPERATION.
Continuous Memory Code 32 indicates that the EGR Yes ~ GO to IDL9S1 .

valve did not reseat fully during vehicle operation.
Possible causes are: No ~ CLEAR Continuous
Memory (REFER to
- Obstructed vacuum hose. Quick Test Appendix).
GO to EGR Valve
- Contaminated EVR filter.
Diagnosis, Section 6.
- Faulty EGR valve.
Key off.
Apply 10in-Hg of vacuum to EGR valve.
While observing EGR valve, release vacuum.
Does EGR valve function in a smooth manner?
NOTE: Repeat test if necessary to ensure
accurate result.

ALL RIGHTS RESERVED

DL
EGR Vacuum Regulator (E~) Test
DL9SIINSPECT VACUUM LINES BETWEEN

EVR SOLENOID AND EGR VALVE
Inspect EGR valve vacuum supply line from EVR Yes ~ GO to IOL961.
solenoid for kinks and/or obstructions.
Is vacuum supply line to EGR valve free of No ~ SERVICE as necessary.
CLEAR Continuous
any obstructions?
Memory (REFER to
RERUN Quick Test.
I
DL96 INSPECT EVR FILTER
Carefully check EVR filter for contamination and/ Yes ~ Unable to duplicate
or obstructions. and/or identify fault at
Is EVR filter condition acceptable? diagnosis using the
EEC-IV Monitor box,
REFER to Section 18
EEC-IV Monitor Box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
~ Appendix). RERUN
~
Quick Test.
No ~ REPLACE EVR filter.

CLEAR Continuous
Memory (REFER to
RERUN Quick Test.

ALL RIGHTS RESERVED

DL
I
DL97 CONTINUOUS MEMORY CODE 33:
CHECK EGR VALVE OPERATION
Continuous Memory Code 33 indicates that the EGR Yes ~ GO to IOL9SI.

valve intermittently did not open when it was
required to. No ~ CLEAR Continuous
Possible causes are: Memory (REFER to
- Faulty EGR valve. GO to EGR Valve
- Open or shorted harness. Diagnosis, Section 6.
Key off.
While observing the EGR valve, slowly apply 10
in-Hg vacuum.
NOTE: EGR valve should begin to open with a
very small amount of vacuum,
approximately 1 to 1.5 in-Hg, and be fully
open with about 4 In-Hg vacuum.
Does EGR valve move freely and smoothly?
DL9al EVR HARNESS CHECK

Disconnect processor 60 pin connector. Inspect CLEAR Continuous
for damaged or pushed out pins, corrosion, loose Memory (REFER to \
wires, etc. Service as necessary. Quick Test Appendix).
Install breakout box and connect processor to RERUN Quick Test.
breakout box.
Enter Output State Check. Refer to Quick Test No ~ REMOVE breakout box.
Appendix. Unable to duplicate
and!or identify fault at
DVOM on 20 volt scale. this time. For further
diagnosis using the
Connect DVOM negative test lead to Test Pin 40 EEC-IV Monitor box,
at the breakout box and DVOM positive test lead REFER to Section 18
to Test Pin 33. (Test Pin 52 for 1.9L CFI). EEC-IV Monitor Box:
Cycle throttle if necessary to indicate greater than Intermittent Fault
10.5 volts. Diagnosis.
Remain at this position. All others, CLEAR
While observing DVOM, grasp the harness closest Continuous Memory
to the EVR connector. Wiggle, shake. or bend a (REFER to Quick Test
small section of the EEC-IV system vehicle Appendix). RERUN
harness while working your way to the dash Quick Test.
panel. ,
Lightly tap EVR solenoid to simulate road shock.
Does DVOM Indicate less than 10.5 volts?

ALL RIGHTS RESERVED
EGR Valve Position (EVP) Sensor Pinpoint

DN
EGR Vacuum Regulator (EVR) Solenoid Test
INote I
84 is received during Quick Test or from Pinpoint Test Step Isal.
IRemember I
To prevent' the replacement of good components, be aware that the following non-EEC area
may be at fault:
Damaged EGR valve
EVP sensor (-9G428-)
Harness circuits: VREF, EVP, SIG RTN, EVR, VPWR
. EVR Solenoid (-9J459-)
EGR valve assembly
EGR and EVR vacuum lines
:S-
*TEST PIN 26@---VREF---~~~iI ~. EVP
VREF ~ SIGNAL
TEST PIN 27@ BR/LG EVP ----tR-<1-C
SIG RTN
TEST PIN 46@---SIG RTN-----+lI--<J
EVP
EVP SENSOR SENSOR
CONNECTOR
TEST PIN 3301-------EVR----~ EVR SOLENOID

VEHICLE HARNESS
TEST PIN 37~VPWR------ CONNECTOR
TEST PIN 57 ~ .


ALL RIGHTS RESERVED

DN
Test Pin 46 SIG RTN

All F-Series/Bronco GY/R
All Others BK/W
Test Pin 26 VREF

All F-Series/Bronco BR/W
All Others O/W
Test Pin 33 EVR

All F-Series/Bronco BR/PK
All Others DG

ALL RIGHTS RESERVED

DN
DN1 ISERVICE CODE 31:

Service Code 31 indicates that the EGR Valve Yes ~ REPLACE EVP sensor.
Position (EVP) sensor signal is less than the Self- REMOVE Jumper.
Test minimum value of 0.2 volts. RERUN Quick Test.
- Faulty EVP sensor. No ~ REMOVE Jumper. ,
GO to ION21.
- Open harness.
- Grounded harness.
- Faulty processor.
Jumper VREF circuit to EVP circuit at the EVP .
DN21 CHECK VREF CIRCUIT VOLTAGE
Key on, engine off. Yes ~ GO to ION31.

Step IC11.
connector.
DN3 I CHECK EVP CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes ~ GO to ION41.

Disconnect processor 60 pin connector. Inspect No ~ SERVICE open circuit.
for damaged or pushed out pins, corrosion, loose REMOVE breakout box.
components. RERUN
Install breakout box and connect processor to Quick Test.
breakout box.
Measure resistance between EVP circuit at the
EVP sensor vehicle harness connector and Test

ALL RIGHTS RESERVED

DN
DN41 CHECK EVP CIRCUIT FOR SHORT TO

GROUND

EVP sensor disconnected. RECONNECT all
components. RERUN
Quick Test.
DVOM on 200,000 ohm scale. No ~ 'SERVICE short circuit.
Measure resistance between Test Pin 27 and Test RECONNECT all
Pins 40, 46 and 60 at the breakout box. components. RERUN
Quick Test.
.
DNSI ATTEMPT
SERVICE CODE 35:
TO GENERATE CODE 31
Service Code 35 indicates that the EGR Valve Yes ~ GO to ION6l.

Position (EVP) sensor signal is greater than the
Self-Test maximum value of 4.81 volts. No ~ GO to ION71.
- Short to power in harness.
DN6 I CHECK VREF CIRCUIT VOLTAGE
Key on, engine off. Yes ~ REPLACE EVP sensor.

RERUN Quick Test.
Measure voltage between VREF circuit and SIG Step IC11.
connector.

ALL RIGHTS RESERVED
EGR Valve Positi.on (EVP) Sensor Pinpoint

DN
ON7 I CHECK EVP CIRCUIT FOR SHORT TO POWER

EVP sensor disconnected. REMOVE breakout box.
RECONNECT EVP
Measure the resistance between Test Pin 27 and RECONNECT all
Test Pins 26 and 57 at the breakout box. components. RERUN
Is each resistance greater than 10,000 ohms? Quick Test.
I
ON 10 SERVICE CODE 84:
CHECK RESISTANCE OF EVR SOLENOID
Service Code 84 indicates a failure in the EGA Yes ~ ,GO to IDN111 .

Vacuum Regulator (EVR) solenoid circuit.
Possible causes are: No ~ REPLACE EVA
- Faulty EVA solenoid solenoid assembly.
- Open harness RERUN Quick Test.
- Shorted harness
. - ' Faulty processor
Disconnect EVR solenoid.
Measure solenoid resistance.
Is resistance within specification per the
following chart?
Resistance
Engine
Specification
4.9L and 5.8L U/8500 20 to 45 ohms
7.5L 100 to 135 ohms
All Others 30 to 70 ohms
ON111 CHECK VPWR CIRCUIT VOLTAGE
Key on, engine off. Yes ~ GO to IDN121.

RECONNECT EVA
Measure voltage between battery negative post solenoid. RERUN Quick
and VPWR circuit at the EVR solenoid vehicle Test.
harness connector.

ALL RIGHTS RESERVED

DN
DN121 CHECK EVR CIRCUIT CONTINUITY
Key off. Yes ~ GO to ION 131 .

No .~ SERVICE open circuit.
Quick Test.
breakout box and EVR circuit at the EVR solenoid
DN131 CHECK EVR CIRCUIT FOR SHORT TO POWER

OR GROUND

REMOVE breakout box..
EVR solenoid disconnected. RECONNECT EVR
Breakout box installed, processor disconnected. solenoid. RERUN Quick
Test.
Pins 37, 40, 46, 57, and 60 at the breakout box. REMOVE breakout box.
RECONNECT all
Is each resistance greater than 10,000 ohms? components. RERUN
Quick Test. If code is
repeated, REPLACE
processor.

ALL RIGHTS RESERVED
EGli Valve Position. (EVP) Sensor Pinpoint

DN
I
DN20 SERVICE CODE 34:
CHECK FOR SERVICE CODE 84
Service Code 34 in Key On Engine Off indicates Yes ~ GO to ION101.

that the EGR valve and/or EGR Valve Position
(EVP) sensOr is not fully seated in the closed
position. The EVP sensor voltage is greater than .the
No ~ GO to ION211.
closed limit voltage of 0.67 volts. Because of the
preload on the installed EVP sensor, it is very
difficult to determine whether the EGR valve is
seated or the EVP sensor is in contact with the
'EGR valve stem.
,Possible causes are:
- Poor continuity at EVP sensor.
- Non-seated EGR valve.
- Faulty EGR valve.
Key off, wait ,10 seconds
Is Code 84 present in Key On Engine Off Self
Test?
I
DN21 CHECK EVP SENSOR AND EGR VALVE
OPERATION '
.~' Key off, wait 10 seconds. Yes ~ GO to ION221.

'. 'Disconnect EVP sensor.
Inspect both the connector on harness and No ~ The original Code 34
sensor for damaged pins, corrosion, loose wires, was the result of poor
etc. Service as necessary. continuity at the EVP
sensor connector or
Remove vacuum line from EGR valve. binding of the EGR
Exercise EGR valve by either applying and valve stem by ,
releasing vacuum with a vacuum pump or contaminants. Testing
depressing and releasing the diaphragm manually. . complete.
Reconnect vacuum line to EGA valve and
'electrical connector to EVP sensor.
i
Rerun Key On Engine Off and Engine Ru'nning

Self-Test.
'. Is Code 34 still present?
ON221 SUBSTITUTE EVP SENSOR ON ORIGINAL EGR

, VALVE

Install a known good EVP sensor on' original EGA
Yes
GO to Section 6 for
EGA valve diagnosis.

valve.
Perform Key On Engir)e Off Quick Test. No The original Code 34
was the result of the
Is Code 34, still present? original EVP sensor.
SEAVICE EVP sensor
as necessary. RERUN
Quick Test.

ALL RIGHTS RESERVED
EGR Valve Position .(EVP) Sensor ~inpoint

DN

CHECK EVP SENSOR AND EGR VALVE
OPERATION
Service Code 32 in Key On Engine Off and Key On Yes ~ GO to IDN26 I.

Engine Running indicates that the EGR valve and/or
EVP sensor voltage is lower than normal in the No ~ The original Code 32
closed position. The EVP voltage is less than the was the result of poor
closed limit voltage of 0.29 volts. Because of the continuity at the EVP
preload of the EVP sensor it is very difficult to sensor connector or
determine whether the EGR valve has malfunctioned binding of the EGR
or the EVP sensor has an abnormally high ~alve stem by
resistance. contaminants. Testing
complete.
- Poor continuity at EVP sensor connector.
- Non-seated EGR valve.
- Faulty EGR valve.
Key off wait 10 seconds.
I

Inspect both the connector at harness and sensor
for damaged pins, corrosion, loose wires, etc.
Remove vacuum line from EGR valve.
Exercise EGR valve by either applying and
releasing vacuum with a vacuum pump or
depressing and releasing the diaphragm manually.
Reconnect vacuum line to EGR valve and
electrical connector to EVP sensor.
Rerun Key On Engine Off and Engine Running
Self-Test.
DN26 SUBSTITUTE EVP SENSOR ON ORIGINAL EGR

VALVE
Key off, wait 10 seconds. Yes ~ GO to Section 6 for

EGR valve diagnosis.
Install a known good EVP sensor on original EGR
valve.
No ~ The original Code 32
Is Code 32 present? original EVP sensor.
SERVICE EVP sensor
as necessary. RERUN
Quick Test.

ALL RIGHTS RESERVED
EGR Valve Position (EVP) Sensor 'Pinpoint

DN
EGR Vacuum Regulator (EVR)' Solenoid Test
TEST'STEP RESULT ACTION TO TAKE
DN40 I SERVICE CODE 33: .

I VERIFY VACUUM IS PRESENT AT EGR VALVE
Service Code 33 in Key On Engine Running Yes ~ REMOVE vacuum .

indicates that the EVP sensor input did not change gauge. GO to ION43 I.
after the EVR solenoid was instructed by the
processor to open the EGR valve. Because a Code, No ~ REMOVE vacuum
84 was not received in the Key On Engine Off Self- gauge. RECO'NNECT
Test, it is known that the EVR solenoid functions EGR valve vacuum'
electrically. It is also known that the EVP sensor is line. GO to IDN411.
in the expected closed valve range because Code
32 and 34 were not received in either Key' On
Engine Off or ,Key On Engine Running Tests.
- Vacuum hose leaks
- Obstructed vacuum hose
- Obstructed EVR solenoid filter
- Faulty EGR valve
Key off.
Disconnect vacuum line from EGR valve.
Connect va~uum gauge at open vacuum line.
Rerun Engine Running Self-Test while observing
vacuum gauge.
Is vacuum greater than 1.5 in-Hg (5 kPa)?
DN41 I VERIFY VACUUM SUPPLY TO EVR SOLENOID
Key off. Yes ~. ,GO to ION421.

Disconnect the vacuum source' to the EVR
solenoid. No ~ CHECK source vacuum
hose to EVR solenoid.
Install a vacuum gauge at source vacuum. SERVICE as necessary.
RERUN Quick Test.
Start engine and check vacuum.
Is vacuum greater than 10 in-Hg (3'3 kPa)?

ALL RIGHTS RESERVED
17..134 EEC-IV Pinpoint Test Procedures

DN
TEST STEP
DN421 CHECK VACUUM HOSE BETWEEN EVR

RESULT
ACTION TO TAKE
SOLENOID AND EGR VALVE
CarefUlly check EGR vacuum hose from EGR

valve to EVR solenoid for obstructions, cracks,
loose connectors, blockage, kinks, leaks, etc.
Yes
CHECK EVR solenoid
filter for obstructions.
REPLACE as
necessary. If OK,
Is va~uum hose in g?od condition? REPLACE EVR
solenoid assembly.
RECONNECT vacuum
hose. RERUN Quick
Test.
No
SERVICE vacuum hose
as necessary. RERUN
Quick Test.
DN431 CHECK EVP SENSOR AND EGR VALVE

OPERATION
Key off, wait 10 seconds. Yes ~ GO to IDN441.

Inspect both the connector at harness and sensor
No
The original Code 33
was the result of poor
continuity at the EVP
signal connector or
binding of the EGR
EGR valve vacuum line disconnected. valve stem 'by
Exercise EGR valve by either applying and contaminants. SERVICE
as necessary. Testing
releasing vacuum with a vacuum pump or complete.
depressing and releasing the diaphragm manually.
Reconnect vacuum line to EGR valve and
electrical connector to EVP sensor.
Rerun Key On Engine Off and Engine Running
Self-Test. .
Is Code 33 stili present?
DN441 VERIFY EGR VALVE VACUUM CONTROL
Key off. Yes ~ RECONNECT EGR

valve (vacuum), GO to
EGR valve vacuum disconnected. IDN451.

Connect vacuum gauge to EGR valve, and apply
2 to 3 in-Hg (6.7 to 10 kPa) for 2 minutes. No GO to Section 6 for
Does EGR valve hold vacuum?

ALL RIGHTS RESERVED

DN
DN45 SUBSTITUTE KNOWN GOOD EVP

SENSOR ON ORIGINAL EGR VALVE

EGR .valve diagnosis.
Install a known good EVP sensor on original EGR
valve.
Rerun Engine Running Self-Test. No ~, The original Code 33
Is Code 33 present? original EVP sensor.
SERVICE EVP sensor
as necessary. RERUN
Quick Test.

CHECK EGR VALVE OPERATION IN ENGINE
RUNNING SELF-TEST WITH EGR VACUUM
DISCONNECTED
Service Code 34 in Key On Engine Running Yes ~ GO to ION511.

indicates that the EVP sensor voltage is greater
than the closed limit voltage of 0.67 volts.
No ~ CHECK EVR solenoid
Possible causes are: filter for obstructions.
- Obstructed EVR solenoid filter REPLACE as
necessary. If OK,
- Faulty EVR soienoid REPLACE EVR
- Faulty EGR valve solenoid assembly.
RECONNECT all
- Faulty EVP sensor vacuum hoses. RERUN.
Key off. Quick Test.
Disconnect vacuum hose from EGR valve and
plug hose.
Is Code 34 present?
DN51 CHECK EVP SENSOR RESISTANCE WHILE

APPLYING VACUUM TO EGR VALVE "

Disconnect vacuum hose at EGR valve. No ~ REPLACE EVP sensor.
Connect vacuum pump to EGR valve. RECONNECT vacuum
DVOM on 200,000 ohm scale. hose. RERUN Quick
Test.
VREF circuit at the EVP sensor while increasing
vacuum to 10 in-Hg (33 kPa).
Does resistance decrease gradually from no
more than 5,500 ohms to no less than 100
ohms? .

ALL RIGHTS RESERVED

DN
DN90 CONTINUOUS MEMORY CODE 32:

CHECK EVP SIGNAL VOLTAGE WHILE
EXERCISING EVP SENSOR
Continuous Memory Code 32 indicates that the EGR Yes ~ EGR valve may have
valve was closed further than normal with the caused Continuous
engine at stabilized operating temperature and at Memory Code 32.
idle, or that the EVP sensor has failed with an CLEAR Continuous
Memory (REFER to
intermittent low voltage spike symptom. Quick Test Appendix).
Possible causes are: GO to Section 6 for
- Faulty EGR valve. No ~ GO to IDN91 I.
- Obstructed vacuum hose.
for damaged or pushed out pins. corrosion, loose
breakout box.
Disconnect vacuum hose at EGR valve.
Key on, engine off.
Pin 46 at the breakout box while doing the
following:
- Slowly increase vacuum at EGR valve to
6 in-Hg (20 kPa), then slowly bleed vacuum
off the EGR valve and lightly tap on EVP
sensor (simulate road shock).
Does Yoltage drop to less than 0.24 YO Its?

ALL RIGHTS RESERVED

DN
DN91 CONTINUOUS MEMORY CODE 32/31:

CHECK EVP SENSOR WHILE IN CONTINUOUS
MONITOR MODE
Continuous Memory Code 31 indicates that Yes ~ GO. to IDN921.

sometime during vehicle operation, the EVP signal
was out of Self-Test range. No ~ GO to IDN93 I .
- Open or shorted circuit.
Very slowly apply 20 kPa (6 in-Hg) vacuum to the
EGR valve.
Slowly bleed vacuum off the EGR valve. Lightly
tap on EVP sensor (simulate road shock).
Wiggle EVP sensor connector.
!)r/VREF~~
"
PROCESSOR
~:V~-:V "
EVP SENSOR
HARNESS
A13542-A
DN92 MEASURE EVP SIGNAL VOLTAGE

WHILE EXERCISING EVP SENSOR

INSPECT connector. If
Disconnect processor 60 pin connector. Inspect connector and
wires, etc. Service as necessary. terminals are ~OOd,
REPLACE EV sensor.
Install breakout box and connect processor to \ CLEAR Continuous
breakout box. Memory (REFER to
Connect a DVOM between Test Pin 27. and Test RERUN Quick Test.
Pin 46 at the breakout box..
DVOM on 20 volt scale. No ~ GO to IDN931.
Re-enter Key On Engine Off Continuous Monitor
mode.
While observing DVOM, repeat Test Step IDN911.
Does the fault occur below 4.25 volts?

ALL RIGHTS RESERVED

DN
DN931 CONTINUOUS MEMORY CODE 31 AND/OR 35:

CHECK EEC-IV
Continuous Memory Code 31 indicated an open in Yes ~ ISOLATE fault and

the EVP or VREF circuit, or a short to SIG RTN SERVICE as necessary.
with the engine at stabilized operating temperature REFER to appropriate
and at idle. figure. CLEAR
Continuous Memory
CODE 31: (REFER to Quick Test
Appendix). RERUN
~~EVP--<,~
yVREF~~~ QUick Test.
7 ~ ~
SIGRTN~ No GO to ION941.
PROCESSOR HARNESS EVP SENSOR
A9600-D
Continuous Memory Code 35 indicated a short to

VREF and/or VPWR, or an open in SIG RTN with
the engine at stabilized operating temperature and
at idle.
CODE 35:
~
/VREF~~
, >-- EVP-O M" ) ,
~. ~ /'
SIG RT~ f----/
PROCESSOR HARNESS EVP SENSOR
A9908-C

mode..
Observe VOM or STAR LED for a fault indication
while performing the following:
- Refer to illustration above by code for
possible circuit faults.
- Grasp the harness close to the sensor
connector. Wiggle, shake or bend a
small
while working your way to the dash panel.
processor.

ALL RIGHTS RESERVED

DN
EGR Vacuum Regulator (EVR) Solenoi~ Test

-
DN941 CHECK PROCESSOR AND HARNESS
CONNECTORS
Key off, wait 10 seconds. Yes ~ For further diagnosis

using the EEC-IV
Disconnect processor 60 pin connector. Inspect Monitor box, REFER to
for damaged -or pushed out pins,. corrosion, loose Section 18 EEC-IV
wires, etc. on both the processor and harness Monitor Box:
connectors. Intermittent Fault
Diagnosis. If the fault
Are connectors and terminals OK? is not identified by the
EEC-IV Monitor Box
Diagnosis, then CLEAR
Continuous Memory
Appendix). GO to
Section 6 for EGA
valve diagnosis.
CLEAR Continuous
Memory (REFER to
RERUN Quick Test.
DN9S1 CONTINUOUS MEMORY CODE 33:

LEAK TEST
Continuous Memory Code 33 indicated that the EGR Yes ~ REMOVE vacuum
valve did not open with the engine at stabilized pump. RECONNECT
temperature and with an EVR solenoid duty cycle EGR valve. GO to
present. ION961.

No ~ REMOVE vacuum
- Obstructed or cracked vacuum hose to EGA pump. RECONNECT
EGR valve. CLEAR
valve.
Continuous Memory
- Open circuit. Code 33 (REFER to
-Quick Test Appendix).
- Faulty EGR valve.
GO to Section 6 for
Key off, wait 10 s~conds. EGA valve diagnosis.

Connect a vacuum pump to EGR valve.
Apply 20 in-Hg (66 kPa) to EGR valve.
Does EGR valve open and maintain vacuum?

ALL RIGHTS RESERVED

DN
DN96 EVR SOLENOID CHECK
Use Continuous Monitor mode (Refer to Quick Yes ~ ISOLATE fault and
Test Appendix). SERVICE as necessary.
CLEAR Continuous
Observe VOM or STAR LED for indication of .a Memory (REFER to
- Grasp the vehicle harness close to the EVR RERUN Quick Test.
solenoid connector, wiggle, shake or bend a
small section of the vehicle harness while
working your way to the processor. No ~ Unable to duplicate
Inspect connectors, terminals for obvious damage this time. For further
or faults. diagnosis using the
Are any faults detected? EEC-IV Monitor box,
REFER to Section 18
EEC-IV Monitor Box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.
DN98 CONTINUOUS MEMORY CODE 34:

CHECK EVP RESISTANCE WHILE APPLYING
VACUUM TO EGR VALVE
Continuous Memory Code 34 indicated that the EGR Yes ~ REMOVE vacuum
valve was open with the engine at stabilized pump. RECONNECT all
operating temperature and at idle. components. CLEAR
Possible causes are: Continuous Memory
Code 34 (REFER to
- Faulty EVR filter. Quick Test A1Pendix).
- Faulty EVR solenoid. GO to DN99 .
- Faulty EGR valve.
Key off.
No ~ REMOVE vacuum
pump. RECONNECT all
Disconnect EVP sensor. components. CLEAR
Continuous Memory
Code 34 (REFER to
Connect vacuum pump to EGR valve. Quick Test Appendix).
DVOM on 200,000 ohm scale. GO to Section 6 for
VREF circuit at the EVP sensor while increasing
vacuum to 10 in-Hg (33 kPa).
Does resistance gradually change from no
more than 5,500 ohms to no less than 100
ohms as the vacuum increases?

ALL RIGHTS RESERVED
EEC-IVPinpoint Test Procedures 17-141
EGR. Valve Position (EVP) Sensor Pjnpoint

DN
DN991 EVR CHECK
Key off. ~
Yes ,- ~ CHECK EVR filter for
obstructions. REPLACE
Disconnect vacuum hose from EGR valve and as necessary. If OK,
plug hose. REPLACE EVR
solenoid. RECONNECT
all vacuum lines.
Is Code 34 present? CLEAR Continuous
Memory (REFER to
RERUN Quick Test.
No ~ Unable to duplicate
, and/or identify fault at
- diagnosis using the
EEC-IV Monitor, box,
/
REFER to Section 18
EEC-IV Monitor Box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
(F.lEFER to Quick Test
, Appendix). RERUN
, Quick Test.

ALL RIGHTS RESERVED
Pinpoint
Vehicle Speed Sensor (VSS) DP
Test
INote I
You should enter this Pinpoint Test only when Service Code 29 is received during Quick
Test or when you have been directed here from Pinpoint Test ITCI.
IRemember I
VSS Harness Circuits
Vehicle Speed Sensor (-9E731-)
Processor Assembly (-12A650-)
Vehicle Speed Sensor, 2.9L Scorpio (-9731-)

FOR 2.9L SCORPIO
PIN 2
TEST PIN 3 &- SR VSS----------~H

TO CHASSIS GROUND ~----------..._c:
TO IGNITION RUN CIRCUIT ~----------~~
* TEST PINS LOCATED ON BREAKOUT BOX.
FOR ALL OTHERS

VEHICLE
FOR ALL OTHERS: SPEED
*TEST PIN 6 0 - - - - - - - VSS DIF (-) --------.J----------.;~ SENSOR (VSS)
TEST PIN 30 VSS DIF (+) ------tl~+------~OJ VEHICLE
- - - - - --I
I HARNESS
'-- - - - - I CONNECTOR
I
I TO 4EAT MODULE :
*TEST PINS LOCATED ON BREAKOUT BOX. I .
_________ -----_-1
FOR 1.9L MA SEFI AIT I

ALL RIGHTS RESERVED
Pinpoint
Test
Test Pin 3 Test Pin 6

Wire Colors
Application VSS DIF (+) VSS DIF (-)
Passenger Car:
1.9L MA SEFI W-BK BL
3.0L EFI Probe BK-R BK-BL
5.0L MA SEFI Lincoln Town Car Y-LB BK-LB
3.8L SC SEFI
3.8L RWD SEFI DG-W BK-W
5.0L MA SEFI
5.0L SEFI
5.0L SEFI, Mark VII DG-W. P-LB
Truck:
3.0L EFI, Aerostar DG-W BK-Y
4.0L MA EFI, Aerostar/Ranger
4.9L, 5.0L EFI, F-Series/Bronco
5.0L, 5.8L EFI E40D, F-Series/Bronco
5.8L E-Series GY-BK PK-O
7.3L E40D Diesel, F-Series
7.5L EFI, F-Series
All Others DG-W O-Y

ALL RIGHTS RESERVED
Pinpoint
Test
VEHICLE SPEED SENSOR (VSS) DRIVE CYCLE
Record and clear EEC-IV Continuous Memory Codes.
Warm engine to operating temperature.
Perform the drive cycle below as appropriate for the vehicle being tested.
Automatic' Transmission
Place the gear selector in LOW and heavily accelerate to 35 mph, then coast down to an idle
and stop the vehicle. Shut engine off.
Manual Transmission
Starting in first gear, shift to second gear and moderately accelerate to 40 mph, then coast
down to an idle and stop vehicle. Shut engine off.
Run Key On Engine Off Self-Test and record Continuous Memory Codes.
DP1 I CONTINUOUS MEMORY CODE 29:

ATIEMPT TO GENERATE CODE 29
Continuous Memory Code 29 indicates that there is Yes ~ GO to IOP21.

insufficient input to the processor from the Vehicle
Speed Sensor (VSS). No ~ Unable to duplicate
Possible causes are: and/or identify fault at
- Faulty VSS. diagnosis using the
EEC-IV Monitor box,
- Open or shorted circuit(s). REFER to Section 18
- Faulty proces~or.
EEC-IV Monitor Box:
Intermittent Fault
Perform Vehicle Speed Sensor Drive Cycle, all Diagnosis.
vehicles except 2.5L CFI and 3.0L EFI Aerostar.
All others, CLEAR
FOR 2.5L CFI and 3.0L EFI Aerostar, can drive Continuous Memory
complaint be verified? (REFER to Quick Test
ALL OTHERS, did Continuous Memory Code 29 Appendix).
repeat?

ALL RIGHTS RESERVED
Pinpoint
'Vehicle Speed Sensor (VSS) DP
Test
DP21 CHECK VEHICLE SPEED SENSOR (VSS)

RESISTANCE
Key off, wait 10 seconds. Yes ~ GO to /OP31.

Disconnect Vehicle Speed Sensor (VSS).
No ~ REPLACE VSS.
DVOM on 2,000 ohm scale. REPEAT Test Step
Measure resistance across VSS.
IOP11, except for 2.5L
CFI and 3.0L EFI
Is resistance between 190 and 250 ohms? Aerostar, VERIFY that
drive complaint was
eliminated.
DP3 I CHECK CONTINUITY OF VSS CIRCUITS
Key off, wait 10 seconds. Yes ~ GO to IOP41.

VSS disconnected.
No ~ SERVICE open
Disconnect processor 60 pin connector. Inspect circuit(s). REMOVE
for damaged or pushed out pins, corrosion, loose breakout box.
components. REPEAT
Install breakout box, leave processor disconnected. Test Step IOP11,
DVOM on 200 ohm scale. except for 2.5L CFI
and 3.0L EFI Aerostar,
Measure resistance between Test Pin 6 at the VERIFY that drive
breakout box and the VSS DIF( -) circuit at the complaint was
VSS vehicle harness connector. eliminated.

breakout box and the VSS DIF(+) circuit at the
VSS vehicle harness connector.
TEST PIN 6 0 - -VSS DIF

TEST PIN 30-- VSS DIF +
-===I ~;
A9695-B
.

ALL RIGHTS RESERVED
Pinpoint
Test
DP41 CHECK VSS CIRCUITS FOR SHORTS

TO POWER OR GROUND
Key off. Yes ~ For 1.9L MA SEFI

A/T:
VSS disconnected. GO to IOP61.
For all others:
For 1.9L MA SEFI AfT, disconnect both 4EAT REMOVE breakout box.
module vehicle harness connectors. RECONNECT
DVOM on 200,000 ohm scale. Iprocjssor. GO to
OP5 .
Pins 37, 40 and 6 at the breakout box. No ~ SERVICE short
Measure resistance between Test Pin 6 and Test circuits(s). REMOVE
Pin 37 at the breakout box. breakout box.
RECONNECT all
Is each resistance greater than 10,000 ohms? cO':Tlponents. REPEAT
Test Step IDP11 ,
except for 2.5L CFI
and 3.0L EFI Aerostar,
VER IFY that drive
complaint was
eliminated.
DPsl REPEAT VSS DRIVE CYCLE WITH A KNOWN

GOOD VSS INSTALLED
Processor connected. Yes ~ REPLACE processor.

Install known good VSS. REINSTALL original
Perform VSS Drive Cycle (Except 2.5L CFI and VSS. REPEAT Test
3.0L EFI Aerostar) then return to this Step. Step IOP1! , except for
2.5L CFI and 3.0L EFI
For 2.SL CFI and 3.0L EFI Aerostar, can drive Aerostar, VERIFY that
complaint be verified? drive complaint was
eliminated.
All others, did Continuous Memory Code 29
repeat?
No ~ The original Continuous
. Memory Code 29 was
the result of the
original VSS. REPLACE
VSS. RERUN Quick
Test. (Testing complete
for 2.5L CFI and 3.0L
EFI Aerostar.)

ALL RIGHTS RESERVED
,Pinpoint
Vehicle Speed Sensot' (VSS) DP
~ Test
,-
.-~
DP6 I CHECK FOR SHORTED 4EAT MODULE
NOTE: The 1.9L MA SEFI A/T has a VSS circuit Yes ~ RECONNECT
input to the 4EAT, module. This test is to ~ssor. GO to
verify that the VSS circuit is not shorted DP5 .
inside the 4EAT module.
Key off.
No ~ Shop
GO to Transmission
Manual Group to
Breakout box installed, processor disconnected. check for short in
4EAT system.
VSS disconnected. ~
Reconnect both 4EAT module vehicle harness

connectors.
Pins 6; 37, and 40 at the breakout box.
.
I
DP10 CONTINUOUS MEMORY CODE 29:
CHECK FOR BATTERY " , . ,
Continuous Memory Code 29 indicates that there is Yes ~ GO to IDP111 .

insufficient input to the processor from the Vehicl~
Speed Sensor (VSS). No ~ CHECK. Fuse 20. If
Possible causes are: OK, SERVICE RRen
, circuit. RECON ECT
- Faulty VSS. VSS. RERUN Quick
Test.
- Open or shorted circuit(s).
- Faulty processor. '.'
:
Turn ignition switch to RUN. ;
,;
Raise vehicle on hoist.
Disconnect VSS.
.. ~

Measure voltage between Pin 1 and Pin 3 of the
VSS vehicle harness connector. ;
, Is voltage greater than 10.5 volts?
PIN3~PIN1
~
VSS VEHICLE
HARNESS CONNECTOR A 13543A
.'-
ALL RIGHTS RESERVED
Pinpoint
Test
DP111 CHECK GROUND TO VSS
Vehicle raised on hoist. Yes ~ GO to IOP121.

Key off. -~
No SERVICE open in VSS
VSS disconnected. wound circuit.
ECONNECT VSS.
DVOM on 200 ohm scale. RERUN Quick Test.
Measure resistance between Pin 1 of VSS vehicle
harness connector and engine block ground.
PIN 1
VSS VEHICLE
HARNESS CONNECTOR
~ A13544A
DP121 CHECK VSS OUTPUT VOLTAGE
Vehicle raised on hoist. Yes , ~ REPLACE 8rocessor.

RECONNE T VSS.
Turn ignition switch to RUN. RERUN Quick Test.
Place transmission in NEUTRAL.
VSS disconnected. No ~ REPLACE VSS.
RERUN Quick Test.
Jumper Pin 1 of harness side of connector to Pin
1 of sensor side of connector, Pin 2 of harness
side of connector to Pin 2 of sensor side of
connector, and Pin 3 of harness side of connector
to Pin 3 of sensor side of connector.
Connect positive lead of DVOM to Pin 2 of
sensor side of connector and ne~ative lead of
DVOM to Pin 1 of sensor side 0 connector.
Observe voltage while slowly rotating rear tire.
Does voltage rise to above 5.5 volts and fall to
below 1.5 volts in a regular cycle? _
PIN 3 PIN 1 PIN 3
PIN1~
~
PIN 2 PIN 2 .-
HARNESS SIDE SENSOR SIDE
OF CONNECTOR OF CONNECTOR
A13545A

ALL RIGHTS RESERVED
EECIV Pinpoint Test Pro~edures 17-149
Fuel Injection Pump Lever PinjJoint

(FIPL) Sensor Test
DQ
INote I
You should enter this Pinpoint Test only ,when a Service Code 23, 53, or 63 is received
during Quick Test. '
IRemember I
To prevent the replacement of ,good components, be aware that the following non-EEC areas
may be at fault: . .
Idle speeds/throttle stop adjustrn'Emt.'
8inding throttle shaft/linkage or speed control linkage.
Choke/high cam system, if equipped.
FIPL sensor (-98989-)
Sensor harness circuits: VREF, FIPL, and SIG RTN
Processor assembly (-128565-)

*TESTPIN46 @,.-....----SIGRTN-----.
TESTPIN47 @ FIPL-----++I
*TEST PIN 26 @ VREF----
FUEL INJECTION FUEL INJECTION

PUMP LEVER (FIPL) PUMP LEVER (FIPL)
SENSOR VEHICLE SENSOR CONNECTOR
HARNESS
CONNECTOR

A12797-B

ALL RIGHTS RESERVED
Fuel Injection Pump Lever Pinpoint

DQ
(FIPL) Sensor Test
Test Pin 26 VREF

E-Series: O/W
F-Series: BR/W
Test Pin 46 SIG RTN

E-Series: BK/W
F-Series: GY/R
Test Pin 47 FIPL

E-Series: DG/LG
F-Series: GY/W
.'
--.--------------------------------------'
ALL RIGHTS RESERVED

(FIPL) Sensor Test
DQ
D01 I
SERVICE CODE 23:
CHECK FOR STUCK THROTTLE LINKAGE
NOTE: If you are directed here because of a Yes ~ GO to 10021.

Key On Engine Running Code 23, but an
Engine ID Code of 5.0 was not received, No ~ SERVICE as necessary.
then go directly to Pinpoint Test Step RERUN Quick Test.
\OJ11.
Visually inspect throttle linkage for binding or
sticking.
Verify the throttle linkage is at mechanical/closed
throttle. Check for binding throttle linkage, speed
control linkage, vacuum linelelectrical harness
interference, etc.
Does throttle move freely and return to closed
throttle position?
D021 SERVICE CODE 53:

Key off, wait 10 seconds. Yes ~ GO to 10031.

Disconnect FIPL sensor vehicle harness connector
at the Fuel Injection Pump. Inspect for damaged No ~ GO to 10041.
pins, corrosion, loose wires, etc. Service as
necessary.
DQ31 CHECK VREF CIRCUIT VOLTAGE
Key off, wait 10 seconds. Yes ~ GO to 100141 for FIPL

sensor adjustment
FIPL sensor disconnected. procedures.
Key on, engine off.
Step IC11.
RTN circuit at the FIPL sensor vehicle harness
connector.

ALL RIGHTS RESERVED

(FIPL) Sensor Test
DQ
DQ4 I CHECK FIPL CIRCUIT FOR SHORT TO POWER

FIPL sensor disconnected. RECONNECT FIPL
DVOM on 200,000 ohm scale. sensor. RERUN Quick
Disconnect processor 60 pin connector. Inspect Test.
wire, etc. Service as necessary. No ~ SERVICE short circuit.
RECONNECT all
Measure resistance between Test Pin 47 and Test components RERUN
Pins 26 and 57 at the breakout box. Quick Test. The original
Code 32 was the result
of the original EVP
sensor. SERVICE EVP
sensor as necessary.
RERUN Quick Test.
I
OQ10 SERVICE CODE 63:
ATTEMPT TO GENERATE CODE 53/23
Key off, wait 10 seconds. Yes ~ REMOVE jumper wire.

RECONNECT FIPL
Disconnect FIPL sensor vehicle harness connector
at throttle body. Inspect for damaged or pushed sensor. GO to 100141
for FIPL sensor
out pins, corrosion, loose wires, etc. Service as
adjustment procedures.
necessary.
Jumper VREF circuit to FIPL circuit at FIPL
sensor vehicle harness connector. No ~ GO to 100111.
NO'FE: If no codes are generated, immedi.
remove jumper and go directly to 0013 .
Is Code 53/23 present (ignore all other
codes)?
OQ111 CHECK VREF CIRCUIT VOLTAGE

FIPL sensor disconnected.
Yes
No
GO to IOQ121 .
~ GO to Pinpoint Test
Step IC11.
Key on, engine off.
RTN circuit at the FIPL sensor vehicle harness
connector.

ALL RIGHTS RESERVED

(FIPL) Sensor Test
DQ
D0121 CHECK FIPL CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes ~ GO to IOQ13\.

FIPL sensor disconnected.
RECONNECT all
Disconnect processor 60 pin connector. Inspect . components. RERUN
breakout box.
Measure resistance between FIPL circuit at the
FIPL sensor vehicle harness connector and Test
Is the resistance less than 5.0 ohms?
D0131 CHECK FIPL CIRCUIT FOR SHORTS TO

GROUND
Key off, wait 10 seconds Yes ~ REPLACE processor.

FIPL sensor disconnected. RECONNECT all
components. RERUN

ALL RIGHTS RESERVED

DQ
(FIPL) Sensor Test
DQ141 CHECK FIPL SENSOR ADJUSTMENT
NOTE: Two people are required to perform this procedure.
Perform Key On Engine Off Self-Test while holding the throttle wide open (WOT).
After last service code has been displayed, remain in Self-Test.
While in Self-Test, place 0.515 inch gauge block Rotunda number T83T-7B200-AH between
the Fuel Pump Lever Travel Screw and the Gauge Boss (Figure 1 and 2).
Cycle the Overdrive Cancel Switch (OCS) once.
Observe Self-Test Output (STO) of the STAR tester for:
Constant Tone, solid Light, or "STO LO" readout means the FIPL adjustment is within
range, cycle OCS to get out of this test.
Beeping Tone, Flashing Light, or "STO LO" erratic readout (4 per second) indicates
adjustment is required.
Beeping Tone, Flashing Light, or "STO LO" erratic readout (1 per second) indicates
adjustment is required.
If tone is undetectable, FIPL may have worn internal substrate. Check by trying to move
sensor.
If adjustment is required see Figure 3:
1. If FIPL sensor and bracket screws are tight and there are no signs of wear between, the
mounted parts, loosen FIPL sensor attachment screws and rotate sensor one way or the
other until a constant tone, solid light, or "STO LO" readout is obtained. Tighten FIPL
sensor attachment screws. REMOVE gauge block; RERUN Quick Test.
2. If bracket shows signs of wear due to movement or vibration, remove epoxy from FIPL
bracket screw heads. Loosen those screws and turn the FIPL/bracket assembly to get
within range then retighten screws and apply epoxy to screw head. REMOVE gauge
block, RERUN Quick Test.
3. If the Service Codes are still present or a steady tone cannot be obtained, REPLACE the
FIPL sensor.
WARNING I
DO NOT TURN THE FUEL PUMP LEVER TRAVEL SCREW. THIS SCREW HAS BEEN
PRESET AND SHOULD NOT BE TAMPERED WITH.

ALL RIGHTS RESERVED

DQ
(FIPL) Sensor Test
FUEL INJECTION PUMP LEVER

(FIPL) SENSOR .
LOW IDLE
ADJUSTMENT SCREW
A12798-B
Figure 1 Top View of Fuel Pump
LOW IDLE ADJUSTMENT

SCREW
FUEL PUMP LEVER
TRAVEL SCREW
(DO NOT ADJUST)
GAUGE BLOCK----~~....m1lIl
GAUGE BOSS-
A12799-B
Figure 2 Throttle Side View

ALL RIGHTS RESERVED

DQ
(FIPL) Sensor Test
FIPL SENSOR ATTACHMENT SCREWS
FIPL BRACKET SCREWS A13546A
Figure 3 FIPL Side View

ALL RIGHTS RESERVED
EEC..IV Pinpoint Test Procedures 17157
Fuel Injection Pu~p' Lever Pinpoint

(FIPL) Sensor . Test DQ
DQ90 CONTINUOUS MEMORY CODE 53:

MONITOR FIPL CIRCUIT UNDER SIMULATED
ROAD SHOCK
Enter Key On Engine Off Continuous MO'1itor Yes ~ GO to I OQ91 1 .

Observe YOM or STAR LED for indication of a No GO to IOQ921.
- Move throttle slowly to WOT position.
lightly tap on FIPL sensor (simulate road
shock).
- Wiggle FIPL harness connector
POWER OR VREF
CIRCUIT ~ .
[
/VREF~~'
) FIPL SIG <> k' ai' ) .
'-SIG.RTN.--'/
PROCESSOR HARNESS FIPL SENSOR
A12808-A
DQ91 MEASURE FIPL CIRCUIT

VOLTAGE WHILE EXERCISING FIPL SENSOR
Key off, wait 10 seconds. Yes DISCONNECT and

INSPECT connectors. If
YOM or STAR LED still connected to STO as in connector and
previous step. terminals are good,
Disconnect processor 60 pin connector. Inspect CLEAR Continuous
Memory (REFER to
GO to IOQ141.
breakout box. No VERIFY harness
Connect a DVOM from Test Pin 47 to Test Pin integrity, GO to
IOQ921.
Key on engine off.
While observing DVOM, repeat Step IOQ90 I.
Does the fault occur below 4.25 volts?

ALL RIGHTS RESERVED

(FIPL) Sensor Test
DQ
DQ921 CHECK EEC-IV VEHICLE HARNESS
Still in Key On Engine Off Continuous Monitor Yes ~ ISOLATE fault.

- Referring to the illustration in Step ID090 I, Appendix). RERUN
No ~ GO to IOQ931.
processor.
DQ931 CHECK PROCESSOR AND HARNESS

CONNECTORS

for damaged or pushed out pins, corrosion, loose diagnosis using the
wires, etc. Service as ne~essary. EEC-IV Monitor box,
REFER to Section 18
Are connectors and terminals OK? EEC-IV Monitor box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.
CLEAR Continuous
Memory (REFER to
RERUN Quick Test.

ALL RIGHTS RESERVED
EECIV Pinpoint Test- Procedures 17159

(FIPL) Sensor Test
DQ
DQ94 CONTINUOUS MEMORY CODE 63:

MONITOR FIPL CIRCUIT UNDER SIMULATED
ROAD SHOCK
Enter Key On Engine Off Continuous Monitor Yes ~ INSPECT connectors. If

mode. Refer to Quick Test Appendix. connector and
terminals are good,
Observe VOM or STAR LED for indication of a CLEAR Continuous
fault while performing the following: Memory (REFER to
- Move throttle slowly to WOT position. RERUN Quick Test.
- Release throttle slowly to closed condition. GO to IOQ141.
- Lightly tap on FIPL sensor (simulate road

No ~ GO to IOQ951.
shock).
- Wiggle FIPL sensor vehicle harness
connector.
S!~SIG VREF~
YFIPL '
0/"14
TO GROUND
Jl
)~ .
SIG. RTN. ,t
FIPLSENSOR
PROCESSOR HARNESS
A12809A
DQ95 CHECK EECIV VEHICLE HARNESS
Still Key On Engine Off Continuous Monitor mode. Yes ~ ISOLATE fault.
Observe VOM or STAR LED for a fault indication REFER to appropriate
while performing the following: figure. CLEAR
Continuous Memory
- Referring to the illustration in Step I OQ94 1
grasp the vehicle harness close to the sensor Appendix). RERUN
connector. Wiggle, shake or bend a small Quick Test.
section of the EECIV system vehicle harness
Also wiggle, shake or bend the EECIV No ~ GO to IOQ961.
processor.

ALL RIGHTS RESERVED

DQ
(FIPL) Sensor Test
DQ961 CHECK PROCESSOR AND HARNESS

CONNECTORS

for damaged or pushed out pins, corrosion, loose diagnosis using the
wires, etc. EEC-IV Monitor box,
REFER to Section 18
Are connectors and terminals OK? EEC-IV Monitor box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.
CLEAR Continuous
Memory (REFER to
- RERUN Quick Test.

ALL RIGHTS RESERVED
Pinp~int
Cylinder Identification (CID) Sensor DR
Test
INote I
You should enter this Pinpoint Test only when Service Code 19 is received during Quick
Test.
IRemember I
Harness circuits: CID(+), CID( -)
CID Sensor (-68288-)

D
"TEST PIN 41
TEST PIN 42
0--0-CID (+)
~ BLlGR -CID (-)
'r-----
, - , - - - - - -,-, DG
; :
--~-'
: ;
LB
CYLINDER IDENTIFICATION
(CID) SENSOR VEHICLE
HARNESS CONNECTOR
TO EDIS
MODULE
PIN 7


ALL RIGHTS RESERVED
Pinpoint.
Cylinder Identification (CID) Sensor DR
Test
DR1 I CONTINUOUS MEMORY CODE 19:

CHECK CID SENSOR RESISTANCE
Continuous Memory Service Code 19 indicates an Yes ~ GO to IOR21.

error ,has been detected in the Cylinder Identification
(CID) sensor input signal. The error could be due to
a "hard fault" or an intermittent condition. On the
1.9L MA SEFI, the CIO sensor is a Variable
Reluctance (VR) device and is used for fuel
No
REPLACE CID sensor.
RERUN Quick Test.
injection synchronization.
Possible causes:
- Faulty CID sensor.
- Faulty processor.
' ,
Key off.
Disconnect CID sensor (located on back of
cylinder head by coil pack).
Measure resistance of CID sensor.
Is resistance between 300 and 600 ohms?
.,
0'

ALL RIGHTS RESERVED
EE~.IV Pinpoint Test Procedures 17163
Pinpoint
Cylinder Identification (.CID) Sensor DR
Test
.. ,
DR2 I CHECK CONTINUITY OF CIO CIRCUITS
Key off. Yes ~ GO to IOR31.
CIO sensor. disconnected.

Disconnect processor- 60 pin connector. Inspect REMOVE breakout bQx.
wires etc. Service as necessary. components. RERUN
Quick Test. ,
OVOM on 200 ohm scale.
breakout box and CID(+) circuit at the CID sensor
Measure resistance' between Test Pin 42 at the
breakout box and CIO( -) circuit at the CIO
Is each reslstanc~ less than 5.0 ohms?
TEST PIN 41 0--o--C1D (+ )-DG ~

TEST PIN 42 0-BUGR -CID (-)- LB
CIDSENSOR
~
VEHICLE HARNESS
CONNECTOR
A13548-A'
"
DR3 I CHECK CIO CIRCUITS FOR SHORTS

CID sensor disconnected. REMOVE breakout box.
RECONNECT all
components. RERUN
Pins 42, 37, 57, 40~' 60 at the breakout box.
Pins 37, 57, 40, 60 at the breakout box.
.'

ALL RIGHTS RESERVED
Pinpoint
Cylinder Identification (CID) Sensor -DR
Test
DR4 I CHECK FOR SHORTS IN PROCESSOR
Key off. Yes ~ GO to IDR51.

Connect processor to breakout box. No ~ REPLACE processor.
CIO sensor disconnected. RECONNECT all
OVOM on 200,000 ohm scale. components. RERUN
Quick Test.
Measure resistance' between Test Pin 41 and Test
Pins 42, 37, 57, 40, 60 at the breakout box.
Measure resistance betWeen Test Pin 42 and Test
Pins 37, 57, 40, 60 at the breakout box.
DRS I CHECK CIO SENSOR OUTPUT

Reconnect CID sensor. No ~ REPLACE CIO sensor.
DVOM on AC scale (to monitor less than 5.0 RECONNECT
volts). processor. RERUN
Start engine. Quick Test.
Measure voltage between Test Pins 41 and 42 at ' -
the breakout box while vearying engine rpm.
Does voltage vary?
DR6 I ATTEMPT TO REGENERATE CODE 19
Key on, engine off. Yes ~ REPLACE processor.

Clear Continuous Memory (refer to Quick Test REMOVE breakout box.
Appendix). RECONNECT all
components. RERUN
Start engi,ne. Quick Test.
Rev engine to greater than 3100 rpm 2 or 3
times. No ~ SERVICE CODE 19 is
Key off. intermittent. INSPECT
harness for possible
intermittent opens or
Is Continuous Memory Code 19 present? shorts. SERVICE as
necessary. If an EEC-
IV Monitor Box is
available, REFER to
Section 18; EEC-IV
Monitor Box:
Intermittent Fault
Diagnosis.

ALL RIGHTS RESERVED
Neutral Drive Switch Pinp~int

FA
Ale Input Test
INote I
You should enter this Pinpoint Test only when a Service, Code 67 or 79 Is received
during Quick Test or you have been direct,ed here from Diagnosis By Symptom.
IRemember I
This, Pinpoint Test is intended to diagnose only the following:
A/C input to processor
Clutch engage switch (-11A152-)
Neutr?ll clutch switch (-11 A152-)
Neutral drive switch (-7A247-)
Neutral gear switch (-7A247-)
Harness circuits: CES, NCS, NDS, NGS, ACC, ACCS and SIG RTN

ALL RIGHTS RESERVED
Neutral Drive Switch Pinpoint

FA
Ale Input Test
Test Pin 10 AIC Input Test Pin 30 NOS

5.0L Mark VII LG/P 1.9L SEFI MA BR/Y
1.9L SEFI MA GR/BK 5.0L Mark VII .
Crown Victorial W/PK
2.3L OHC MA
Grand Marquis
2.5L CFI
3.0L SHO PK/LB 3.8L RWD, SC R/LB
3.8L SC, RWD
1.9L CFI/EFI
5.0L SEFI MA
2.3L HSC GY/O
1.9L CFI/EFI
2.3L OHC, 2.3L MA
2.9L Car
3.0L Car PlY
3.0L Truck BK/Y
5.0L Mustang
4.0L Aerostar
4.9L, 5.0L, 5.8L, 7.5L 3.0L Probe R/BL
2.3L HSC 2.3L Truck
W/BK
2.3L Truck 2.9L Truck
T/Y
2.9L Truck
2.9L Car
4.0L Ranger
4.9L E-Series BR/W
3.0L Probe PU/BK 5.8L E-Series
2.5L CFI
LB/Y
5.0L E-Series LB/W
5.8L F-Series/Bronco GY/Y
7.5L F-Series
Test Pin 46 SIG RTN

1.9L MA SEFI LG/B
2.9L Scorpio BR
3.0L Probe LG/Y
7.5L F-Series
7.3L F-Series Deisel
All Others BK/W

ALL RIGHTS RESERVED

Ale Input Test
FA
FA1 I CODE 67 SYSTEM IDENTIFICATION ..
A Code 67 resulted from the voltage being high at:

- Pin 10 = A/C input
I
- Pin 30 = Neutral drive
while cranking the engine or during KOEO test.
.- A/C circuit shorted to power
- Neutral clutch/drive circuits open
- Neutral clutch/drive switch open
- Faulty processor
- Starter relay disconnected during Self-Test.
For Manual Transmissions:

1.9L CFI, 2.5L, 5.0L, 5.8L, 7.5L
.... GO to IFA101.
.....
3.0L SHO and 4.9L
.... GO to IFA71.
Jl""'"
1.9L EFI, 1.9L MA SEFI, 2.3L, 2.9L, 3.8L SEFI ....Jl""'" GO to IFA21.
Super Charged and 5.0L SEFI Mass Air
For E40D Transmissions:

4.9L, 5.8L, 7.5L, 7.3L Diesel
......... GO to IFA101.
For all other Automatic Transmissions:

1.9L MA SEFI, 3.0L Probe
....
..... GO to IFA131.
.
For all other engines:
.... GO' to IFASI.
......

ALL RIGHTS RESERVED
17168 EEe-IV Pinpoint Test ~rocedures

FA
Ale Input Test
FA2 I CHECK NEUTRAL GEAR/CLUTCH INPUT
Key off, wait 10 seconds. Yes ~ GO to IFA31.

Verify A/C is off, if so equipped.
No ~ GO to IFASI.
Pin 46.
1. With transmission in NEUTRAL and clutch up.
2. With transmission in GEAR and clutch down.
NEUTRAL NEUTRAL GEAR SWITCH

DRIVE "OPEN IN ANY GEAR
CIRCUIT ,n _ " "
TEST PIN 30 . . - -......
CLUTCH SWITCH OPEN WHEN

CLUTCH PEDAL IS UP
TEST PIN 46 0 BKIW SIG. RTN.--.-..J
A9853-D
FA31 CHECK NEUTRAL GEAR/CLUTCH

INPUT INTEGRITY
Key off. Yes ~ For vehicles with

Ale:
Breakout box installed. GO to IFA101.
Processor disconnected.
All others:
DVOM on 200 ohm scale. REPLACE processor.
Measure resistance between Test Pin 30 and Test RERUN Quick Test.
Pin 46 at the breakout box with transmission in
any GEAR and the clutch pedal up.
No ~ GO to IFA41.

ALL RIGHTS RESERVED
EEC-IVPinpoint Test Proced':lres 17-169

FA
Ale Input Test
. FA4 r CHECK FOR SHORT TO GRO'UND

Ale:
Breakout box installed. GO to IFA101.
All others:
Disconnect clutch interlock switch. REPLACE processor.
Pin 46 at the breakout box. No ~ SERVICE short circuit.
Is resistance greater than 10,000 ohms? RECONNECT
processor.
RERUN Quick Test.
FASI CHECK NEUTRAL GEAR/CLUTCH

SWITCH
Key off. Yes ~ GO to IFA61.

No ~ REPLACE open
Breakout box installed, processor disconnected switch(es). REMOVE
breakout box.
Locate Neutral Gear switch (on transmission) and RECONNECT all
Clutch switch (at clutch pedal linkage). components. RERUN
Disconnect vehicle harness at both switches and Quick Test.
inspect connectors for pushed back pins.
Measure resistance across the Neutral Gear
switch terminals with transmission in NEUTRAL
and across the Clutch switch terminals with the
clutch pedal down.
Is each resistance less than S ohms?

ALL RIGHTS RESERVED

FA
Ale Input Test
FA6 I CHECK NEUTRAL GEAR/CLUTCH HARNESS

A/C:
DVOM on 200 ohm scale. GO to IFA101.
For all others:
Vehicle harness disconnected at the Neutral Gear REPLACE processor.
switch and Clutch switch.
Measure resistance between Test Pin 30 and the No ~ SERVICE open circuit.
Neutral Gear switch harness connector and REMOVE breakout box.
between Test Pin 30 and the Clutch switch RECONNECT all
harness connector. components. RERUN
Quick Test.
Measure resistance between Test Pin 46 and the
Neutral Gear switch harness connector and
between Test Pin 46 and the Clutch switch
harness connector.
FA7 I CHECK CLUTCH ENGAGE SWITCH
NOTE: For 4.9L engines, the clutch pedal must Yes ~ For vehicles with
be down during KOEO test; if not, a A/C:
Code 67 will result. GO to IFA101.
Key off. For all others:
Disconnect processor 60 pin connector. Inspect REPLACE processor.
wires, etc. Service as necessary. No ~ SERVICE open circuit.
RECONNECT all
DVOM on 200 ohm scale. components.
Clutch pedal down.
Pin 46.
TO IGNITION
SWITCH
CLUTCH INTERLOCK
SWITCH
1
SWITCH J
CLUTCH ENGAGE
TEST PIN 30
4(
10 STARTER
RELAY
-_'"'""-.....i4I.....-~~.
A8911B

ALL RIGHTS RESERVED
EEC-IV Pinpoint Test ProcedUres 17-171

FA
Ale Input Test
FA8 I CHECK NEUTRAL DRIVE INPUT
Key off, wait 10 seconds. Yes ~ - For vehicles with

A/C:
Verify heater control is in OFF position, if so GO to IFA101.
equipped.
For all others:
Verify transmission is in NEUTRAL or PARK. REPLACE processor.
Disconnect processor 60 pin connector.. Inspect
No ~ Go to IFA91.
Install breakout box, leave processor connected.

Key on, engine oft
breakout box and chassis ground.
Is voltage less than 1.0 volt?
TO IGNITION
SWITCH
TEST PIN 30 ~~
TO STARTER
RELAY
NEUTRAL DRIVE CIRCUIT
CLOSED IN PARK AND NEUTRAL A9475-C

ALL RIGHTS RESERVED

FA
Ale Input Test
FA9 I CHECK NEUTRAL DRIVE SWITCH
Key off, wait 10 seconds. Yes ~ SERVICE open in

vehicle harness Neutral
Breakout box installed, processor disconnected. Drive circuit. REMOVE
DVOM on 200 ohm scale. breakout box.
RECONNECT all
Locate the Neutral Drive switch. components. RERUN
Disconnect vehicle harness from the Neutral Drive Quick Test.
switch and measure resistance across the switch.
Is resistance less than 5 ohms? No ~ REPLACE Neutral Drive
switch. REMOVE
breakout box.
RECONNECT all
components. RERUN
Quick Test.
I
FA10 CHECK AIC INPUT
NOTE: Before entering this test, verify Shift Yes ~ SERVICE short to
Selector is in PARK for E40D vehicles power in AIC circuit.
only, and A/C selector is off. If A/C was REMOVE breakout box.
on, rerun Quick Test. If code 67 or 79 is RECONNECT all
present, continue with this test. components. RERUN
Disconnect processor 60 pin connector. Inspect Quick Test.
wires, etc. Service as necessary. No ~ For vehicles with
Install breakout box, leave processor disconnected. E40D transmission:
GO t Pinroint Test
Key on, engine off. l
Step TC1 .
For all others:
Measure voltage between Test Pin 10 at the REPLACE processor.
breakout box and chassis ground. REMOVE breakout box.
Is voltage greater than 1.0 volt? RECONNECT all
components. RERUN
AIC CLUTCH CIRCUIT Quick Test.
i-T~p'N1o~-lL 11
)AC
I __ ...,
I ~ '- BATT~+) I
L!~T.!!.N~ _ _ _ACD _ _ _ J
2.3L HSC CAR, 2.3L & 4.9L TRUCK
A13549A

ALL RIGHTS RESERVED
EEC~IV Pinpoint Test Procedures 17-173

FA
Ale Input Test
I
FA11 CHECK AIC INPUT CIRCUIT
.NOTE: A low idle with A/C on could be the Yes ~ REPLACE processor.
result of the processor not receiving, or REMOVE breakout box.
recognizing the A/C input on Pin 10. RECONNECT all
components. RERUN
Key off, wait 10 seconds. Quick Test. .
for damaged or pushed out pins, corrosion, loose No ~ SERVICE open in AIC
wires, etc. Service as necessary. circuit. Refer to the
appropriate engine
Install breakout box, leave processor disconnected. schematic in Engine
Supplement Sections.
DVOM on 20 volt scale. REMOVE breakout box.
Key on, engine off. RECONNECT all
components. RERUN
AIC on. Quick Test:
Pin 40.
TEST PIN 100

1I
AlC CLUTCH CIRCUIT
)AC
A11501-B

ALL RIGHTS RESERVED

FA
Ale Input Test
FA 13/ CHECK NEUTRAL DRIVE INPUT

Verify transmission is in PARK or NEUTRAL. RECONNECT all
Disconnect processor 60 pin connector. Inspect components. RER UN
Quick Test.
No ~ Key off. GO to IFA141.
breakout box.
Disconnect 16 pin connector from the 4EAT
module.
Key on, engine off.
Is voltage less than 1.0 volt?
BRN TO
TEST PIN 30 0 NDS~ 4EAT
MODULE
(3.0L PROBE R1BL)
A13550-A
,
..

ALL RIGHTS RESERVED

A/C. Input Test
FA
FA 141 CHECK NDS CIRCUIT CONTINUITY BETWEEN

PROCESSOR AND 4EAT MODULE
Key off. Yes ~ GO to Transmission

Shop Manual Group for
4EAT module 16 pin connector disconnected. 4EAT system diagnosis.
Breakout box installed. REMOVE breakout box
and RECONNECT all
Disconnect proces.sor. components when
testing is complete.
Measure resistance between Test Pin 30 at the No ~ SERVICE open circuit.
breakout box and the NDS pin at the 4EAT REMOVE breakout box.
module vehicle harness connector. RECONNECT all
components. RERUN
Is resistance less than 5.0 ohms? Quick Test.
----~
BRN ~
-
TEST PIN 30 0-- NOS
(3.0L PROBE RlBl)
- - -
------ X
~
10-
~ I--
~~
~
1000-1....-
4EAT MODULE
16-PIN VEHICLE
HARNESS CONNECTOR
A13551-A

ALL RIGHTS RESERVED

FA
Ale Input Test
FA151 CHECK FOR NONFUNCTION AIC WITH HIGH

IDLE
NOTE: A high idle with A/C instrument panel Yes ~ GO to IFA161.

switch on but A/C not functioning could
be the result of no signal at A/C clutch. No ~ SERVICE open in AIC
circuit. REMOVE
breakout box.
Disconnect processor 60 pin connector. Inspect RECONNECT all
for damaged or pushed out pins, corrosion, loose components. RERUN
wires, etc. Service as necessary. Quick Test.

Disconnect AIC clutch connector.
Key on, engine off.
AIC on.
Measure voltage between input pin on fan
connector and Test Pin 40 at the breakout box.
TESTPIN~~
TEST PIN 10
AlC
:Ill
AlC CLUTCH CIRCUIT
AlC --
DEMAND CYCLE
SWITCH PRESSURE
SWITCH
L...---II:'. 10 BATIERY A8912-B

ALL RIGHTS RESERVED

FA
Ale Input Test
FA161 CHECK CONTINUITY OF AIC CLUTCH . :
Key off. Yes ~ Fault was probably due

to AIC clutch
Breakout box installed, processor disconnected. connector not seated.
AIC clutch disconnected. CHECK for damage or
loose pins in clutch
DVOM on 200 ohm scale. connector. REMOVE
breakout box.
Measure the resistance across both pins on the RECONNECT all
AIC clutch. components. RERUN
Quick Test.
Is resistance between 2.14 and 3.34 ohms?

RECONNECT all
VentilatinglClimate
Control Shop Manual
Group for AIC clutch
service.
FA 171 CHECK CONTINUITY OF AIC CYCLE

PRESSURE SWITCH CIRCUIT
Key off, wait 10 seconds. Yes ~ EEC-IV system OK.

for damaged or pushed out pins, corrosion, loose components. REFE~ to
wires, etc. Service as necessary. Ventilating/Climate
Control Shop Manual
Install breakout box, leave processor disconnected. Group for AIC cycle
AIC cycle pressure switch disconnected. pressure switch service.
AIC demand switch on.

RECONNECT all
For 4.9L only: components. RERUN
Measure the resistance between Test Pin 43 at Quick Test.
the breakout box and battery positive side of the
AIC cycle pressure switch connector.
For all vehicles:
Measure the resistance between Test Pin 10 at
the breakout box and negative side of the AIC
cycle pressure switch connector.

ALL RIGHTS RESERVED

FA
Ale Input Test
FA18 CHECK AC DEMANDI AC CYCLE PRESSURE

SWITCH CIRCUIT FOR SHORT TO POWER
Key off. Yes ~ VERIFY operation of

AIC demand and AIC
Disconnect processor 60 pin connector. Inspect cycle pressure
for damaged or pushed out pins, corrosion, loose switch(s). IF OK,
wires, etc. Service as necessary. SERVICE short circuit
RE-EVALUATE
Install breakout box, leave processor disconnected. symptom. REMOVE
AIC demand switch off. breakout box.
RECONNECT
DVOM on 20 volt scale. processor.
Key on.
No ~ REFER to Ventilating I
Climate Control Shop
breakout box and chassis ground. Manual Group AIC
Is voltage greater than 1.0 volts? Clutch Diagnosis.
If OK, REPLACE
processor
FA20 CHECK NDS CIRCUIT FOR SHORT TO

GROUND OR CLOSED NEUTRAL DRIVE
SWITCH

Routine 211, High Idle.
wires, etc. Service as necessary. No ~ SERVICE short circuit
or closed neutral drive
Install breakout box, leave processor disconnect. switch. REMOVE
breakout box.
Place transmission in DR IVE. RECONNECT
DVOM on 200,000 ohm scale. processor.
RE-EVALUATE
Measure resistance between Test Pin 30 and Test symptom.
Pin 40/60 at the breakout box.

ALL RIGHTS RESERVED
Pinpoint
IBrake 00/.0(800) Test
FD
INote I
You should enter this Pinpoint Test only when a Service Code 74 or 75 is received
during Quick Test.
IRemember I
. .
To prevent the replacement of good components, be aware that the following non-EEC areas ,
may be at fault:
Brakelamp, Brake switch, and fuse.
BOO circuit

Mustang
BATT (+)
% FUSE
, STOPLAMP
SWITCH
TEST PIN 2 0- RlLG - BOO fi~it R / L G - - - - - -__
12A581 14401
HARNESS HARNESS
STOPLAMP
A9211-a

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACES.

ALL RIGHTS RESERVED
Pinpoint
IBrake On/Off (BOO) Test
FD

Thunderbird/Cougar
BATT (+)
l
r
FUSE
STOPlAMP
SWITCH
*TEST PIN 50-LG BOO ~+--- LG - - - - - - .

12A581 14401 STOPLAMP
HARNESS HARNESS
A9212-B
Taurus/Sable (Except 3.0L SHO)
BATI(+)
~ FUSE
3.0LEFI
2.5LCFI
TEST PIN 2 e_ Rl
_ L_G_ _ BOO
-(i)g
00
RlLG
%STOPLAMP
SWITCH
3.8L SEFI AXOD 12A581 0 0 14401

TEST PIN 5 HARNESS. HARNESS
STOPLAMP
A9213-B


ALL RIGHTS RESERVED
Pinpoint
FD
Taurus/Sable (3.0L SEFI SHO)
BA1(:~SE
tsroPLAMP
(1)
0 SWITCH
00
. 00
-TEST PIN 5 0-- RlLG - - BOO ~~~---R/LG:-----
12A581 14401
HARNESS HARNESS STOPLAMP
A9214B
Continental (3.8L SEFI AXOD)
BATT(+)
~
~ ::LAMP
SWITCH
TEST PIN 5 ~ R/LG - - BOO -~~"/J
12A581
WLG-----..
14401
A9215B
* TEST PINS LOCATED ON BREAKOUT BOX. .


ALL RIGHTS RESERVED
Pinpoint
FD
Crown Victoria/Grand Marquis
BATT (+)
l FUSE
r STOPLAMP
SWITCH
*TEST PIN 2 0--LG - - BOO-@~

g r*-\1"'l'----- LG - -...
12A581 14401
HARNESS HARNESS
STOPLAMP
A9216-B
Mark VII
BATT (+)
l FUSE
r STOPLAMP
SWITCH
TEST PIN 2 0- LG BOO mLG--
12A581 ~ 14401
HARNESS
STOPLAMP
HARNESS
A9217-B


ALL RIGHTS RESERVED
EEe-IV Pinpoint Test Procedures . 17183
IBrake On/Off (BOO) Pinpoint

Test
FD
Town Car
BATI(+)
o0 0 0
DOD 0 STOPLAMP
SWITCH
[] 0 0 0
DGIW
DGIW
*TEST PIN 5 0 - -
DOD 14401
HARNESS
12A581
HARNESS STOPLAMP
A13552-A
Bronco II/Ranger (Except 4.0L)
BATT (+)
l FUSE
r STOPLAMP
SWITCH
*TESTPIN2 & - L G - e o 0 - i d D -+-tt----- LG

12A581 0 0 14290
HARNESS 0 HARNESS
STOPLAMP
A9218-B
* TEST PINS LOCATED ,ON BREAKOUT BOX.


ALL RIGHTS RESERVED
Pinpoint
FD
Bronco II/Ranger (4.0L)
BATT (+)
i FUSE
STOPLAMP
SWITCH
"TEST PIN 2 O~LG

_ _ BOO ~ LG
12A581~
HARNESS
14290
HARNESS
STOPLAMP
A13553A
Aerostar
BATI(+)
~ FUSE
STOPLAMP
SWITCH
"TEST PIN 20- RllG-BOO AlLG

12A581
14401 STOPLAMP
HARNESS
HARNESS
- A9221B


ALL RIGHTS RESERVED
Pinpoint
[Brake On/Off (BOO) FD
Test
E-Series
BATT (+)
*TEST PIN 20- LG - BOO-tf-~+KJ ~~+-LG---.

~::~MP
SWITCH
12A581 14401
HARNESS HARNESS
A9222B
F-Series/Bronco (Except 7.3L Diesel)
BATT (+)
~ FUSE
STOPLAMP
SWITCH
*TEST PIN 20- LG - BOO--l+-+-+-3EI-+o
12A581
HARNESS
A9223B


ALL RIGHTS RESERVED
Pinpoint
FD
F-Series/Bronco (7.3L Diesel)
BATT (+)
~ FUSE
r STOPLAMP
*TEST PIN 20- LG - BOO~~:.J\. /r..>I-f----LG
12A581 14401
A9229-B


ALL RIGHTS RESERVED
Pinpoint
FD
FD1 ISERVICE CODE 74:

VERIFY BRAKE WAS PRESSED
Service Code 74 indicates that when the brake Yes ~ GO to IFD21.

pedal was depressed during the Engine Running
Self-Test, the BOO signal did not cycle high.
No ~ RERUN Engine
Possible causes are: Running Self-Test.
- Brake pedal not depressed and released during
>
PRESS brake once
the Engine Running Self-Test. during test.
.'
- Open stoplamp circuit (BAIT (+) side of BOO
splice).
- Short to GROUND.
.
- Faulty processor.
Did you press brake during the Engine
Running' Self-Test? ..
NOTE: On some vehicles it is necessary to
depress and release the brake after the
Dynamic Response code 1(0) but before
the brief WOT.
FD2 I CHECK FOR BOO CIRCUIT CYCLING

Disconnect processor 60 pin connector. Inspect ~ REMOVE breakout box.
for damaged or pushed out pins, corrosion, loose RERUN Quick Test.
,~ires, etc. Service as necessary.
In'stall breakout box, leave processor disconnected. No ~ GO to IFD31.
Measure voltage between Test Pin 2 and Test Pin
40 at the breakout box while depressing and
releasing brake.
Does the voltage cycle?
FD31 CHECK BOO CIRCUIT FOR SHORT TO

GROUND
Key off. Yes ~ GO to Lighting Shop

Breakout box in~talled, processor disconnected. Manual Group to
SERVICE stoplamp
DVOM on 200,000 Ohm scale. circuit.
Disconnect 12A581 to 14401 harness connector
shown on pinpoint test IFD I cover pages. No ~ SERVICE short circuit.
Measure resistance between Test Pin 2 and Test REMOVE breakout box.
Is resistance greater than 10,OQO ohms? components. RERUN
Engine Running Self-
Test.

ALL RIGHTS RESERVED
Pinpoint
IBrake On/Off (BOO) Test'
FD
FD51 SERVICE CODE 75:

CHECK FOR BOO CIRCUIT CYCLING
Service Code 75 indicates that while the brake Yes ~ REPLACE processor.
pedal was released during the Engine Running Self- REMOVE breakout box.
Test, the BOO signal was high. RERUN Quick Test.
- Brake pedal depressed during entire Engine No ~ GO to IFD61.
Running Self-Test.
- Open BOO/stoplamp circuit (between processor
and stoplamp ground).
- Short to POWER. ."
- Faulty processor.
Measure voltage between Test Pin 2 and Test Pin
40 at the breakout box while depressing and
releasing the brake.
FD6 I CHECK BOO CIRCUIT FOR SHORT TO POWER
Key off. Yes ~ SERVICE short circuit.

RECONNECT all
DVOM on 20 volt scale. components. RERUN
Disconnect 12A581 to 14401 harness connector Engine Running Self-
shown on pinpoint test IFD I cover pages. Test.
breakout box and engine block ground. No ~ GO to IFD71.
Is voltage greater than 1.0 volt?
FD7 I CHECK CONTINUITY OF BOO CIRCUIT
Key off. Yes ~ GO to Lighting Shop

Breakout box installed, processor disconnected. Manual Group to
SERVICE stoplamp
DVOM on 200 ohm scale. circuit.
12A581 to 14401 harness connector disconnected.
breakout box and BOO circuit at the 12A581 REMOVE breakout box.
harness connector. RECONNECT all
Is resistance less than 5 ohms? components. RERUN
Test.

ALL RIGHTS RESERVED
Pinpoint
FD
I
FD10 SERVICE CODE 74:
VERIFY BRAKE WAS PRESSED
Service Code 74 indicates that when the brake Yes ~ GO to IFD111.

pedal was depressed and released during the
Engine Running Self-Test, the BOO signal did not
cycle high and low.
No ~ RERUN Engine
Running Self-Test.
Possible causes are: PRESS brake once
- Brake pedal not depressed and released during during test.
the Engine Running Self-Test.
- Brake pedal depr~ssed during entire Engine
Running Self-Test.
- Open BOO/stoplamp circuit.
- Short to GROUND or POWER.
- Faulty processor.
. Did y~u press ~rake during the Engine
Running Self-Test?
NOTE: On some vehicles it is necessary to .
depress and release the brake after the
dynamic response code 1(0) but before
the brief WOT.
FD111 CHECK OPERATION OF BRAKE LAMPS
Key on. Brakelamps ~ GO to IFD121.

Check brakelamp operation. operate
normally
Brakelamps ~ GO to IFD131.
never on
Brakelamps ~ GO to IFD141.
always on
FD121 CHECK FOR BOO CIRCUIT CYCLING
Key off, wait 10 seconds. Yes ~ REMOVE processor.

Install breakout box, leave processor disconnected. No ~ SERVICE open in BOO
circuit between
processor and BOO
Measure voltage between Test Pin 2 (Test Pi.n 5 connection to stoplamp
for all 3.8L, 5.0L, and 3.0L SHO engines) and circuit. RERUN Quick
Test Pin 40 at the breakout box while depressing Test.
and releasing brake.

ALL RIGHTS RESERVED
Pinpoint
FD
FD131 CHECK FOR STOPLAMP CIRCUIT POWER TO

14401 or 14290 HARNESS CONNECTOR
Key off. Yes ~ SERVICE open circuit

between BOO
Disconnect connector indicated on Pinpoint Test
IFD I Schematic (12A581 harness connector to connection to stoplamp
either 14401 or 14290 harness connector). circuit and stoplamp
ground. RECONNECT
DVOM on 20 volt scale. harness connector.
Measure voltage between BOO circuit on 14401 RERUN Quick Test.
or 14290 harness connector and chassis ground
while depressing the brake. No ~ VERIFY operation of
Is voltage greater than 10 Yolts? brake switch. If OK,
SERVICE open circuit
between BAn (+)
supply to circuit and
BOO connection to
stoplamp circuit.
RECONNECT harness
.. connector. RERUN
Quick Test.
FD141 CHECK FOR SHORT TO POWER AT 14401 or

14290 HARNESS CONNECTOR
Key off. Yes ~ GO to IFD1SI.

Disconnect connector indicated on Pinpoint Test
IFD I schematic (12A581 harness connector to No ~ VER IFY operation of
either 14401 or 14290 harness connector). brake switch. If OK,
DVOM on 20 volt scale. SERVICE short to
power. RECONNECT
Key on, engine off. harness connector.
Measure voltage between BOO circuit on 14401 RERUN Quick Test.
or 14290 harness connector and chassis ground
(brake released).
Is voltage less than 1.0 Yolt?
FD151 CHECK FOR SHORT TO POWER IN

PROCESSOR
Key off. Yes ~ SERVICE short to

Reconnect 12A581 to 14401 or 14290 harness power between
connector. processor and 12A581
to 14401 or 14290
Disconnect processor. harness connector.
Key on, engine off. RERUN Quick Test.
Are brake lamps still on?
RERUN Quick Test.

ALL RIGHTS RESERVED
Power Steering P~essure Pinpoint

FF
Switch (PSPS) Test
INote I
IRemember I
may be at fault:
Idle speed/throttle stop adjustment
Binding throttle shaft/linkage or speed control linkage
Power steering pressure switch (-3N824-)
Harness circuits: PSPS, and SIG RTN
*TEST PIN 24 @_-----Y.;../L....;;G--PSPS--+--+--+-I POWER STEERING

PRESSURE SWITCH (PSPS)
(TEST PIN 2 FOR 3.0L SHO-SEFI SIG RTN -~~""""4 VEHICLE HARNESS
AND 3.8L AXOD-SEFI, TEST PIN CONNECTOR
23 FOR 2.5L CFI, TEST PIN 3
FOR 2.3L OHC EFI)
TEST PIN 46 .~--------...

A9658-E
Test Pin 46 SIG RTN Test Pin 24 (23,2,3) PSPS

All F-Series/Bronco GY/R 3.0L Probe BR/R
All Others BK/W All Others Y/LG

ALL RIGHTS RESERVED
Power Steering Pressure Pinpoint

FF
Switch (PSPS) Test
FF1 IATIEMPT
SERVICE CODE 52:
TO ELIMINATE CODE 52
NOTE: Some vehicles are equipped with a Power Yes ~ GO to IFF21.

Steering Pressure Switch software
strategy, but do not have Power Steering
hardware released for the engine/vehicle
No ~ REPLACE PSPS.
RERUN Quick Test.
application. When Service Code 52 is
received in Key On Engine Off, check to
see if the vehicle is equipped with Power
Steering. If not, disregard servicing the
Code 52. Return to Quick Test Section to
service other codes.
Service Code 52 indicates that the Power Steering
Pressure Switch (PSPS) circuit is open.
- Faulty PSPS switch.
- Open harness.
- Faulty processor.
Disconnect PSPS.
Jumper PSPS circuit to SIG RTN circuit at the
PSPS vehicle harness connector.
Rerun Key On Engine Off Self-Test. .
FF2 I CHECK CONTINUITY OF PSPS CIRCUITS

PSPS disconnected. REMOVE breakout box.
RECONNECT all
Install breakout box, leave processor disconnected. No ~ SERVICE open circuit.
RECONNECT all
Measure resistance between Test Pin 46 at the components. RERUN
breakout box and SIG RTN circuit at the PSPS Quick Test.
23 for 2.5L CFI, Test Pin 2 for 3.0L SHO-SEFI
and 3.8L AXOD-SEFI, Test Pin 3 for 2.3L OHC
EFI) at the breakout box and PSPS circuit at the
PSPS vehicle harness connector.
Is each resistance less than 5. ohms?

ALL RIGHTS RESERVED
EEC-IV Pinpoint rest Procedures 17-193

FF
Switch (PSPS) Test
.-
TEST STEP RESULT .~ ACTION TO TAKE
FF3 I CHECK PSPS OPERATION
Key off. Yes ~ REPLACE PSPS. RE-

Install tachometer. EVALUATE symptom.'
Start engine, allow to idle in NEUTRAL/PARK.
Disconnect PSPS. No ~ GO to IFF41.
,
Does rpm Increase?
FF4 I CHECK PSPS CIRCUITS FOR SHORTS

,
Key off, wait 10 seconds. Yes .~ SERVICE short in
PSPS disconnected. harness. REMOVE
breakout box.
for damaged or pushed out pins, corrosion, loose components. RE-
wires, etc. Service as necessary. EVALUATE symptom.
DVOM on 200,000 ohm scale. No ~ REPLACE processor.
Measure resistance between Test Pin 24' (Test Pin REMOVE breakout box.
23 for 2.5L CFI, Test Pin 2 for 3.0L SHO-SEFI RECONNECT all
and 3.8L AXOD-SEFI, Test Pin 3 for 2.3L OHC components. RE-
EFI) and Test Pin 46 at the.. breakout box. EVALUATE symptom.
Is resistance less than 10,000 ohms?
FF5 I ENGINE RUNNING SERVICE CODE 52
NOTE: Some vehicles are equipped with a Power Yes ~ GO to IFF61.

Steering Pressure Switch software
strategy, but do not have Power Steering
hardware released for the engine/vehicle No ~ RERUN Quick T~st.
application. When Service Code 52 is

received In Key On Engine Running,
check to see If the vehicle Is equipped
with Power Steering. If not, disregard
servicing the Code 52. Return to Quick
Test Section to service other codes.
Engine Running Service Code 52 indicates that the
Power Steering Pressure Switch (PSPS) did not
change states due to the switch staying' either open
or closed.
- Faulty PSPS switch.'
- Open or grounded harness circuit.
- Faulty processor.
Old you turn the steering wheel at least
one-half turn within 1 to 2 seconds after
engine 10 code?
NOTE: Make sure the front wheels are centered
(no load condition).

ALL RIGHTS RESERVED
17194 EECIV Pinpoint Test .Procedures

FF
Switch (PSPS) Test
FF6 DETERMINE WHETHER THE

PROCESSOR CAN IDENTIFY AN OPEN
CIRCUIT
Key off, wait 10 seconds. Yes ~ GO to IFFSI.

PSPS disconnected.
Run Key On Engine Off Self-Test. No ~ GO to IFF71.
Is Code 52 present?
FF7 CHECK PSPS CIRCUITS FOR SHORTS
Key off, wait 10 seconds. Yes ~ SERVICE short circuit.

PSPS disconnected.
RECONNECT all
for damaged or pushed out pins, corrosion or 'Quick Test.
loose wires, etc. Service as necessary.
Install breakout box, leave processor disconnected. No ~ REPLACE processor.
RECONNECT all
Measure resistance between Test Pin 46 and Test components. RERUN
Pin 24 (Test Pin 23 for 2.5L CFI, Test Pin 2 for
..
Quick Test.
3.0L SHO-SEFI and 3.8L AXOD-SEFI, Test Pin 3
for 2.3L OHC EFI) at the breakout box.
Is resistance 10,000 ohms or less?
FF8 CHECK PSPS STATE WITH KEY ON ENGINE

OFF VS. RUNNING
Key off, wait 10 seconds. Yes ~ GO to IFF91.

for damaged or pushed out pins, corrosion, loose No ~ GO to IFF111 .
breakout box.
..
Reconnect PSPS.
Key on, engine off.
23 for2.5L CFI, Test Pin 2 for 3.0L SHO-SEFI
and 3.8L AXOD-SEFI, Test Pin 3 for 2.3L OHC
EFI) and Test Pin 46 at the breakout box.
Start engine.
Does resistance remain less than 10 ohms
between Key On Engine Off and Engine
Running?

ALL RIGHTS RESERVED

FF
Switch (PSPS) Test
FF9 CHECK PSPS STATE WITH ENGINE RUNNING

NO LOAD VS. LOAD
Engine idling. Yes ~ PSPS system OK,

REMOVE breakout box
Breakout box installed, processor connected. and RETURN to Quick
Test Step 5.0 to
PSPS connected.
continue Diagnostics.
Clutch is not depressed on 3.0L SHO-SEFI
manual vehicles. No ~ GO to IFF10 I.
Measure the resistance between Test Pin 24 (Test
Pin 23 for 2.5L CFI, Test Pin 2 for 3.0L SHO-
SEFI and 3.8L AXOD-SEFI, Test Pin 3 for 2.3L
OHC EFI) and Test Pin 46 at the breakout box.
Turn the steering wheel at least one-half turn then
return.
Does resistance change from less than 10
ohms to infinity (indicating PSPS opening),
then returning to 10 ohms or less when
steering wheel is returned to center position?
FF10 CHECK FOR PSPS ALWAYS CLOSED VS.

POWER STEERING HYDRAULIC
PRESSURE WITH ENGINE RUNNING
At this point in the Diagnostics there are only two Yes ~ GO to Power Steering
possible causes for the original Code 52 Engine Pressure Diagnosis
Running: Group in Shop Manual,
looking for low
- PSPS (switch) that will not open. pressure.
- Low available hydraulic pressure.
No ~ Original Code 52
Engine Running was a
Substitute original PSPS with a known good result of a bad PSPS
PSPS. (switch). REMOVE all
equipment and
Run Engine Running Self-Test. (Turn steering CONTINUE, if
wheel at least one-half turn after Engine 10 code.) necessary, with any
other Diagnostics.

ALL RIGHTS RESERVED

FF
Switch (PSPS) Test
FF11 CHECK FOR PSPS ALWAYS OPEN

VS. POWER STEERING HYDRAULIC
PRESSURE WITH ENGINE RUNNING
At this point in the Diagnostics there are two Yes ~ GO to Power Steering
possible causes for the original Code 52 Engine Pressure Diagnosis
Running: Group in Shop Manual,
looking for high
- PSPS (switch) that always remains open during pressure.
Engine Running.
- Excessively high hydraulic pressure. No ~ Original Code 52
Engine Running was a
Key off, wait 10 seconds. result of a bad PSPS
(switch). REMOVE all
Substitute original PSPS with a known good
equipment and
PSPS.
CONTINUE, if
Run Engine Running Self Test. (Turn steering necessary, with any
wheel at least one-half turn after Engine 10 cod.e.) ot~er Diagnostics.

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
INote I
You should enter this Pinpoint Test only when a Service Code 41, 42, 65, 85, 86, 91, 92 or 93 is
received during Quick Test or when directed here from Diagnosis By Symptom or Pinpoint Test ~.
IRemember I
may be at fault:
Ignition Coil EGR Valve and Gasket

Distributor Cap Air Filter
Distributor Rotor Fuel Contamination, Engine Oil
Fouled Spark Plugs Poor Power Ground
Spark Plug Wires Fuel Pressure
CANP Problems Manifold Leaks, Intake/Exhaust,
Intercooler Leaks
PCV Valves (see note below)
Engine Not at Normal Operating
Distributorless Ignition System Temperatures
HEGO Sensor Fuel Injector

HEGO Signal and Ground Circuit Processor Ass.embly
HEGO Sensor Connection Harness circuits: HEGO GRD, HEGO,
INJ. 1 - 8, VPWR and SIG RTN
Vacuum Systems
NOTE: Fuel contaminated engine oil may affect 41, 42, 91 and 92 Service Codes, so if it
is suspected, remove the PCV from the valve cover, and rerun Quick Test. If the
problem is corrected, then change the engine oil and filter.

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H

All CFI
-TEST PIN 37 o~-=R_-VPWR--------"""l

TEST PIN 57 0 R V P W R - - - - - - - - - - - . , .L....- -,
TEST PIN 58 0 T/R INJ. 1 - - - - - - - - - - - - - - - - . . . . ,
TO
GROUND
TEST PIN 490--0--HEGOGND~ HEATED EGO
~
~'-
~
VEHICLE HARNESS
CONNECTOR
INJECTOR
POWER GROUND_ 0 I .
-:- IGNITION
TEST PIN 29 0 DGIP HEGO SIGNAL - - - - RUN CIRCUIT

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A9472-C

ALL RIGHTS RESERVED
EECIV Pinpoint Test' Procedures 17199
IFuel Control Pinpoin~

Test
H
I Pinpoint Test Schematic I

1.9L MA SEFI
FUSE LINK TO IGNITION

POWER GROUND ..Lr----~ ~ RUN CIRCUIT
PIN 29 eGA/BL-HEGO SIGNAL
- ~~ HARNESS
HEGO VEHICLE
CONNECTOR
PIN 49 0-BK- HEGO GND. - - - - - - - - - - - c : : : @ H E G O GROUND

CYL 1 CYL 2 CYL 3 CYL 4
~ij dj G ~~~~;:RS
PIN 37 0---t-W/R--VREF
PIN 57 e--J
PIN58~y_,INJ1-----BA/LB~t J59 J12 13
PIN 59 0--- GR/R _INJ 2 -----~--- BRN

PIN 12 @-.Y/O-INJ3 -. W
PIN 13 0---GA/O-INJ 4 - - - - - - - - - - - - - - - - T

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H

3.8L SEFI, 3.8L SC SEFI and 3.0L SHO SEFI
FUSE IGNITION RUN CIRCUIT

PIN 29 a--- HEGO -R SIGNAL ----~~~~ LINK
POWER
GROUND ::
RIGHTIREAR HEGO VEHICLE
HARNESS CONNECTOR
PIN 49 crfL- HEGOGND ---------~

PIN 43 c:>-- HEGO UF SIGNAL ----~
POWER
GROUND
LEFT/FRONT HEGO VEHICLE
HARNESS CONNECTOR
PIN59~INJ.2
PIN 58 0 T INJ.~~~FRONTOF_
PIN 12 ~INJ. 3 ENGINE
PIN 13 ~INJ. 4
~:~ ~ : LG :~j:~
: ,VPWR 6
~:~:~=: ' W PIN 13 PIN 14 PIN 15

CYLI DER AND INJECTOR
-TEST PINS LOCATED ON BREAKOUT BOX. LOCATIONS ARE THE SAME
ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. IE CYL. -= INJ. - ETC A12814-B
Test Pin 29 Right HEGO (#1) Test Pin 43 Left HEGO (# 2)

3.0L SHO SEFI DG/P 3.0L SHO SEFI DB/LG
3.8L AXOD SEFI DB/LG 3.8L AXOD SEFI DG/P
All Others T/O All Others T/R

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H

S.Ol SEFI and S.Ol SEFI Mass Air
IGNITION RUN CIRCUIT

FUSE
PIN 298 DG/P HEGO-R SIGNAL----- LINK
POWER
GROUND
WRIGHT HEGO VEHICLE
HARNESS CONNECTOR
PIN 498 0 HEGO-LGND------...olt::E> FUSE
PIN 43 e DB/LG HEGO SIGNAL LINK
POWER
GROUND ':
CYL 1 2 3 4
INJECTORS
5 6 7 8
PIN 42 PIN
52
*CYLINDER AND INJECTOR
LOCATIONS ARE THE SAME
*TEST PINS LOCATED ON BREAKOUT BOX. IE CYL. = INJ. = ETC A9471-e

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H

2.3L OHC MA CAR
Trucks with 2.3L MA, 2.9l MA, 4.0L, 4.9l and S.8l Engines
FUSE
LINK
TO IGNITION
POWER GROUND RUN CIRCUIT
;!~ ~ >-: D~/~ -_-_H:.G~ ~G_N~L _-_-_-_-_-_-_-_-_-_-_-_...A_ " HEGO VEHICLE

I PIN 16 &-BKIW _ _S_'G_R_T_N___________ HARNESS CONNECTOR
~ __ _ _ _ _ !R~~K_O~L! _ _ _ _ _ _ _
PIN 49 ~O - - HEGO GND --------~
PIN 58 0 INJ. BANK 1 -------------~"'fIHI_+l'IJ+.~M_+l~
PIN 59 )-T/R _ _ INJ. BANK 2 - - - - - -........I!"tt-~+_+.._tI~
PIN 57 @-R --VPWR - - - " " " ,
PIN 37 0 - R - - V P W R - - - ' ! . ...~...- .......~.....................-.......
INJ BANK 2 INJ. BANK 1
1..-4 CYLINDERJ
~-- 6 CYLINDER----..
~ - - - 8CYLINDER---~

Test Pin 58 INJ BANK 1

2.3L MA Truck
LG/W
2.9L MA Truck
All Others TIO

ALL RIGHTS RESERVED
IFuel Control . Pinpoint.

.Test
H

All Other EFI
FUSE
BREAKOUT LINK TO IGNITION
BOX PIN NO. POWER GROUND ~ ~RUN CIRCUIT .
PIN 290 DG/P HEGO SIGNAL ~ HEGO VEAIClE
HARNESS CONNECTOR
HEGO GROUND
PIN 49 e....O--HEGO G N D . - - - - - - - - - - c 3 )
PIN 58 E> INJ. BANK 1-------~~~___:=___,..- .....~iRoIjo___j~~
PIN
PIN
PIN
37e
59 @
R
57 E> R
INJ. BANK 2
VPWR
VPWR
,INJ. BANK 2 INJ. BANK 1
: 1.4 CYLINDER.l
.....- - 6 CYLINDER---I~
...- - - 8 CYLINDER----+!.
A947G-B

Test Pin 58 INJ BANK 1 Test Pin 59 INJ BANK 2

2.3L DIS 'Truck 1.9l EFI T/O
lG/W
2.9l Truck
All Others T/R
1.9l EFI T/R
All Others TIO

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
PASSENGER CAR ENGINES

1.9L/2.5L 2.3L 3.0L 3.8L ALL
HSC SHO SC OTHER
CFI EFI SEFI SEFI APPLICATIONS
ENGINE 13 -17 PSI 45-60 PSI 28-33 PSI 30-40 PSI 30-45 PSI
RUNNING 90 -120 kPa 310 - 415 kPa 193 -227 kPa 210 - 280 kPa 210 - 310 kPa
KEY ON 13 -17 PSI 50-60 PSI 30-45 PSI 35-40 PSI 35-40 PSI
ENGINE 90 -120 kPa 345 - 415 kPa 210-310 kPa 240 - 280 kPa 240 - 280 kPa
OFF
LIGHT TRUCK ENGINES

ALL OTHER
4.9L EFI APPLICATIONS
RUNNING 310-415 kPa 210- 310 kPa
KEY ON 50-60 PSI 35-45 PSI
ENGINE
OFF 345 -415 kPa 240- 310 kPa

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
INJECTOR BANK' RESISTANCE

SPECIFICATION TABLE #1
PASSENGER CAR ENGINES LIGHT TRUCK ENGINES

VALUES ARE IN OHMS VALUES ARE IN OHMS
1.9L
.. 2.3L 2.3L 2.9L/3.0L 2.3L 2.9L/3.0L 5.0L/S.8L
HSC OHC 4.9L '7.5L
EFI . EFI EFI EFI EFI EFI EFI
1.2 6.0 7.0 5.0 7.0 5.0 3.0
TO TO TO TO TO TO TO
1.8 8.0 9.5 6.5 9.5 . 6.5 4.0
SINGLE INJECTOR RESISTANCE

SPECIFICATION TABLE #2
PASSENGER CAR ENGINES LIGHT TRUCK ENGINES

VALUES ARE IN OHMS VALUES ARE IN OHMS
1.9L/ 2.3L ALL OTHER ALL OTHER
1.9L 2.3L/3.0L
2.5L OHC/ ENGINES ENGiNES
3.0L EFI WITH EFI
EFI CFI EFI WITH EFI
15.0 13.0
2.0 1.0 15.0 13.0 TO -TO
TO TO TO TO 18.0 16.0
2.7 2.0 18.0 16.0

ALL RIGHTS RESERVED
17206 EEC-IV. Pinpoint Test Procedures
Pinpoint
IFuel Control Test
H
H1 I CHECK FUEL PRESSURE
HEGO Engine Running codes 41 and 91 indicate Yes ~ GO to IH2/.

the system is always lean.
HEGO Engine Running codes 42 and 92 indicate No ~ GO to Section 11 for
Electric Fuel pump and
the system is always rich.
fuel pressure regulator
NOTE: For vehicles with dual HEGOs, codes 41 checks.
and 42 refer to right or rear HEGO
sensor; codes 91 and 92 refer to left or
front HEGO sensor.
Install fuel pressure gauge.
Verify that manifold vacuum is connected to the
fuel pressure regulator if applicable.
Start and run engine at idle.
Refer to Fuel Pressure Specification Table.
Is fuel pressure within specification for the engine
being tested?
For No Starts:
If engine will not run, cycle the key off to on
several times. ..
Refer to Fuel Pressure Specification Table.
Is fuel pressure within specification for the
engine being tested?

ALL RIGHTS RESERVED
EECIV Pinpoint Test Procedures o 17207
Pinpoint
IFuel Control Test
H
H2 ICHECK SYSTEM'S ABILITY TO HOLD FUEL

PRESSURE
Key on, engine off. Yes ~ For No Starts:

GO to IH31.
Does fuel pressure remain at specification for
60 seconds? For Runs Rough,
Misses or Fuel
Service Code (41, 42,
91, 92):
REMOVE fuel pressure
gauge.
For SEFI:
Go to IH91.
For All Others:

GO to IH41.
No ~ For SEFI:
GO to IH91.
All Others:
GO to IH61.
H3 I FUEL DELIVERY TEST
NOTE: Verify fuel quality; air and/or water will Yes ~ The EEC-IV system is
also pressurize and look like acceptable not the cause of the
fuel delivery. No Start. REMOVE the
fuel pressure gauge.
Key off. RECONNECT the
inertia switch. REFER
Fuel pressure gauge installed. to Section 2 for other
Pressurize fuel system per step [HI] . No Start routines.
Locate and disconnect the inertia switch.

No ~ REMOVE fuel pressure
Crank engine for 5 seconds. gauge. RECONNECT
inertia switch. GO to
Does pressure drop greater than 5 psi. (34 IH41.
kPa.) by the end of the 5 second crank cycle?

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
H4 ICHECK RESISTANCE OF INJECTOR(S) AND

HARNESS
Key off, wait 10 seconds. Yes ~ GO to IHSI.

for damaged or pushed out pins, corrosion, loose No ~ For EFI
wires, etc. Service as necessary. GO to IHSI.
Install breakout box, leave processor disconnected. For SEFI:
SERVICE open or short
DVOM on 200 ohm scale. in VPWR or injector
For EFI: circuit of the suspect
injector(s). If OK,
- Measure resistance of INJECTOR BANK 1 REPLACE injector.
between Test Pin 37 and Test Pin 58 at the REMOVE breakout box.
breakout box. Record resistance. RECONNECT
processor. RERUN
- Measure resistance of INJECTOR BANK 2 Quick Test and
between Test Pin 37 and Test Pin 59 at the Cylinder Balance Test.
breakout box. Record resistance.
For NO START:
- Refer to Injector Resistance Specification SERVICE open in
Table #1. VPWR circuit.
For SEFI:
For CFI:
- From cylinder balance test: Measure resistance SERVICE open or short
between the suspect INJECTOR circuit Test Pin in harness/connector If
and Test Pin 37 at the breakout box. Record OK, REPLACE injector.
resistance. REMOVE breakout box.
RECONNECT
- For No Starts: Pick any injector and measure processor. RERUN
resistance between that INJECTOR circuit's Test Quick Test.
Pin and Test Pin 37 at the breakout box.
Record resistance.
- Refer to Injector Resistance Specification
Table #2.
For CFI:
- Measure resistance of INJECTOR circuit
between Test Pin 37 and Test Pin 58. at the
breakout box. Record resistance.
- Refer to Injector Resistance Specification
Table #1.
Is each resistance within specification for the
appropriate engine?

ALL RIGHTS RESERVED
II.....F_u_e_l_c_o_D_tr_o_I , L....-.P_i;_:_:_:_D_t-.l L...._"_--.i

TEST'STEP RESULT ~ ACTION TO TAKE
H5 TISOLATE FAULTY INJECTOR CIRCUIT
Key off. Yes ~ GO to IH61:

No.' .~ SERVICE open, or short .
Disconnect all injectors on suspect bank. in VPWR or injector
DVOM on 200 ohm scale. circuit of the suspect
injector(s). If OK"
Connect one injector and measure resistance REPLACE injector.
between Test Pin 37 and either Test Pin 58 or 59 'REMOVE breakout box.
as appropriate. RECONNECT processor
Disconnect that injector and repeat process for and injectors. RERUN
each of the remaining injectors. Quick Test.
,
Refer to Injector Resistance Specification
Table #2. .
'.
Is each resistance within specification for the
appropriate engine?
i
H6 TCHECK INJECTOR DRIVER SIGNAL
Requires standard non-powered 12 volt test lamp. Yes ~ For all SEFI vehicles:
Key off. RECONNECT processor
Breakout box installed. GO to Section 4 for
injector testing and
Connect processor to breakout box. cleaning instructions.
For EFI:
-
.
Connect test lamp between Test Pin 37 and
After any servicing,
RERUN Quick Test
and Cylinder Balance
Test Pin 58 at the breakout box. Test.
- Connect test lamp between Test Pin 37 and 59
at the breakout box. For all other engines:
GO To IH71.
For SEFI:
- Connect test lamp between Test Pin 37 and the
suspect injectors Test Pin at the breakout box.
No ~ No light:
VERIFY 12 volt at"Test
For eFt: Pins 37 and 57.
- Connect test lamp between Test Pin 37 and Bright light:
Test Pin 58 at the breakout box. CHECK injector circuit
Crank or start engine. for shorts to ground.
NOTE: Properly operating systems will show a If system checks OK,
d.im glow on the lamp. REPLACE processor.
Is glow on lamp dim? REMOVE breakout box.
RERUN Quick Test.

ALL RIGHTS RESERVED
IFuel Control Pinpoint

Test
H
H7 ICHECK EXTERNAL SOURCE FOR FUEL

PRESSURE PROBLEM
Key off. Yes ~ REMOVE pressure

gauge. SERVICE as
Pressurize fuel system per Test Step ffiI] . necessary. REFER to
For EFI: Fuel/Engine Shop
Manual Group for
- Visually look for fuel leaking at fuel injector service procedure. After
O-rings, fuel pressure regulator, and fuel rails. servicing leak, RERUN
Quick Test.
For CFI:
- Remove air inlet tube at the fuel charging No ~ For EFI:
assembly. GO to IHsl.
- Visually look for fuel leaking at the air horn For CFI:
inlet, fuel injector O-ring, fuel pressure regulator REMOVE pressure
and fuel line to fuel charging assembly. gauge. Fuel delivery
system is OK. Problem
Is there a visible leak?
is in an area common
to all cylinders, Le. fuel
injector, air/vacuum
leak, fuel
contamination, EGR,
HEGO GND. CHECK
MAP frequency, etc.
He I INJECTOR BALANCE TEST
Connect tachometer to engine. Run engine at idle. Yes ~ Fuel delivery OK.
Problem is in an area
Disconnect and reconnect the injectors one at a common to all
time: Note rpm drop for each injector. cylinders i.e. air/
vacuum leak, fuel
Does each injector produce at least a 100 rpm
contamination, EGR,
momentary drop? HEGO GND. CHECK
NOTE: ISC will attempt to re-establish rpm. MAP frequency etc.
No ~ GO to Section 4 for
injector testing and
cleaning instructions.
After any servicing,
RERUN Quick Test.

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
H9 I CYLINDER BALANCE TEST:

SEFI ENGINES ONLY
The Cylinder Balance Test switches each injector Yes' .~ For Vehicles With
OFF and ON one at a time. Service codes Service Code 41/91:
correspond to the cylinder number, (e.g. Service GO to IH111.
Code 30 indicates a problem with cylinder No.3, a
Service Code 90 indicates a pass.) The Cylinder For Vehicles With
Balance Test is designed to aid in the detection of Service Code 42/92:
a weak or non-contributing cylinder. The Pinpoint . GO to IH231.
Test Steps are designed to isolate only EEC-IV
related problems. For All Others:
Refer to Quick Test Appendix for detailed Fuel delivery is OK.
information about Cylinder Balance Test. Problem is in an area
common to all
Run the Engine Runr:ling Self-Test. cylinders, Le., air/
After the last repeated code, wait 5-10 seconds. vacuum leak, fuel
"Goose" throttle lightly (not wide-open-throttle). contamination, EGA,
HEGO GND, intercooler
Cylinder Balance Test will be performed. Time of
test is approximately 2-3 minutes. leaks (3.8l Super-
Charge - Section 8).
Is Code 90 present? CHECK MAP
frequency, etc.
No ~ GO to IH41.
.
CYLINDER BALANCE TABLE
SERVICE CODE VS. CYLINDER
SERVICE CODE 90 10 20 30 40 50 60 , 70 80 77*
CYLINDER/INJECTOR
1 2 3 4 5 6 7 8
NUMBER RERUN
PASS TEST
BREAKOUT BOX
58 59 12 13 14 15 42 52
PIN NUMBER
* If throttle is touched (moved) during Cylinder Balance Test, Service Code 77 will appear, indicating test
was not completed.

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
H11 I
SERVICE CODE 41/91:
FUEL CONTROL ALWAYS LEAN
NOTE: For vehicles with dual HEGOs, code 41

refers to the right or rear HEGO sensor.
Code 91 refers to the left or front HEGO
Yes . For engines with:
- MAP sensors.
GO to IH121.
sensor. - Vane Air Flow
HEGO Engine Running codes 41 and 91 indicate Meters GO to
the system is always lean. IH131.
Run engine at 2000 rpm for 2 minutes. - Mass Air Flow
Meters GO to
..
IH141.
Is Code 41/91 present? No GO to IH201.

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
H121 CHECK HEGO SENSOR ON ENGINES WITH

MAP SENSORS
NOTE: Vacuum/air leaks in non-EEC-IV areas Yes ~ GO to IH1SI.

could also cause Code 41/91. Check for:
- Leaking vacuum actuator (e.g. No ~. REPLACE HEGO
A/C control motor) sensor. RECONNECT
MAP sensor vacuum
- Engine sealing line. RERUN Quick
Test.
- EGR system
- PCV system
- Lead contaminated HEGO sensor
Key off.
Disconnect appropriate HEGO sensor from vehicle
harness.
For vehicles with 4 wire HEGO:
- Connect DVOM to HEGO SIGNAL and HEGO
GND at the HEGO sensor connector.
For all others:
- Connect DVOM to HEGO SIGNAL at the sensor
Disconnect and plug vacuum line at MAP sensor.
Apply 10-14 in. Hg. (33-46 kPa) to MAP sensor.
Start engine and run at approximately 2,000 rpm
for 2 minutes.
Does the DVOM indicate greater than 0.5 volts
within 2 minutes?
HEGO SIGNAL---~~~-""~
POWER GROUND r'r.l .//_~
(' 1
'CI
KEY POWER ~\..;'I J4.

"'=1'0
1- - FOR2.i MA,2.9L MAt - - 1
4.0L, 4.9L, AND 5.8L EFI: I
I HEGO GROUND I
I
L SIG
_ _ (TRUCK
RTN _ _ .ONLY) ..JI
HEGO SENSOR CONNECTOR A13569-A

ALL RIGHTS RESERVED
lFuel Control
Pinpoint
Test
H
rEST STEP RESULT ACTION TO TAKE

VANE AIR FLOW AIR METER
NOTE: Vacuum/air leaks in non-EEC-IV areas Yes GO to Ijt1sl .

could also cause-Code 41. Check for:
Leaking vacuum actuator No REPLACE HEGO
(e.g. A/C control motor). sensor. REMOVE pencil
from Air Meter.
Engine sealing. REINSTALL air cleaner.
RERUN Quick Test.
EGR system.
PCV system.
Lead/silicone contaminated HEGO
sensor.
Unmetered air leak between Vane Air
Flow Meter and throttle body.
Key off.
Disconnect HEGO sensor from vehicle harness
Remove air cleaner to. gain access to air meter
inlet. Using a standard wood lead pencil, prop the
air meter door partway open.
Connect DVOM to HEGO SIGNAL at the sensor
connector and battery negative post.
Start the engine and run at approximately 2000
rpm for 2 minutes.
Does the DVOM indicate greater than 0.5 volts
within 2 minutes?
HEGO SIGNAL----~~~~
POWER GROUND--"P.!I"'-6...,..tl~
KEY POWER ---~ ..........c:~I~.
HEGO SENSOR
CONNECTOR
A11606-A

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H

MASS AIR SENSOR
NOTE: The purpose of this test is to verify the Yes ~ GO to IH151.

HEGO sen~or can generate greater than
0.5 volts during Engine Running SelfTest. No ~ REPLACE HEGO
Any Vacuum/air leaks in non-EEC-IV areas could sensor. RERUN Quick
also cause Code 41/91. Check for: Test.
- Leaking vacuum actuator (e.g.
AIC control motor).
- Engine sealing.
- EGR system..
- PCV system.
- Unmetered air leak between Mass Air Flow
sensor and throttle body.
- Lead contaminated HEGO sensor.
Key off.
Disconnect appropriate HEGO sensor from vehicle
harness.
For vehicles with 4 wire HEGO:
- Connect DVOM to HEGO SIGNAL and HEGO
GND at the HEGO sensor connector.
For all others:
- Connect DVOM to HEGO SIGNAL at the sensor
Rerun Engine Running Self-Test and monitor
HEGO sensor voltage.
Is the voltage greater than 0.5 volts at the
end of Self-Test?
HEGO SIGNAL ----J.,.,r,~,...~~~

. ,. ~
POWER GROUND ffr1 {( '0'0
KEY POWER ~~U4~
"=IQ
1- - 4.0l,
FOR2.iL. MA,2.9L MAt-
4.9l, AND 5.8l EFI:
- ~1
I
I HEGO GROUND I
IL SIG RTN (TRUCK ONLY) .JI

ALL RIGHTS RESERVED
17-216 EEe-IV Pinpoint Tes~ Procedures
IFue" Control Pinpoint

Test
H
H151 CHECK CONTINUITY OF HEGO SIGNAL AND

HEGO GROUND CIRCUITS
Key off. Yes ~ GO to IH161.

.-
Inspect HEGO GND at the engine (3-wire HEGO
only). No ~ SERVICE open circuit.
processor, HEGO
sensor, and any other
Install breakout box, leave processor disconnected. components that are
disconnected or
HEGO disconnected.
removed. RERUN
For truck only with 4 wire HEGO:
- Measure resistance between Test Pin 49 and
Test Pin 46 at the breakout box and HEGO
GNP at the HEGO vehicle harness connector.
For 2.3L MA Car:
- Measure resistance between Test Pin 49 at the
breakout box and HEGO GND at the HEGO
For all others:
breakout box and HEGO SIGNAL at the vehicle
harness connector.
For vehicles with dual HEGO:
breakout box and HEGO SIGNAL at the vehicle
harness connector.
.Jn1
HEGO SIGNAL
~~
:(~~~) /I
POWER GROUND
KEY POWER
~'~
~-
,r- - - - - - - - - - -- --
FOR 2.3l MA, 2.9l MA, 4.0l,
--,
I
I 4.9l, AND S.8l EFt: I
,
I HEGOGROUND
SIG RTN (TRUCK ONLY)
I
:
I _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .J
,_
HEGO VEHICLE
HARNESS CONNECTOR A9891-D

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
H161 CHECK H/EGO CIRCUIT FOR SHORT TO

GROUND
Key off. Yes ~ GO to IH171.

HEGO disconnected. No ~ SERVICE short circuit.
DVOM on 200,000 ohm scale. RECONNECT processor
Measure resistance between Test Pin 29 and Test and HEGO sensor.
Pins 40 and 49 oat the breakout box. RERUN Quick Test.
For truck only with 4 wire HEGO:
Test Pins 40 and 46 at the breakout box.
For Vehides With Dual HEGO:
H171 CHECK HEGO SENSOR FOR SHORT TO

GROUND
Key off. Yes ~ For Engines With:

Breakout box installed, processor disconnected. - MAP sensor
GO to IH1SI.
HEGO disconnected. - Vane Air Meter
DVOM on 200,000 ohm scale. GO to IH191.
- Mass Air Flow
Measure resistance between PWR GND and Meter. REMOVE
HEGO SIGNAL at the HEGO sensor connector. breakout box.
For truck only with 4 wire HEGO: RECONNECT
HEGO sensor.
- Measure resistance between PWR GND, HEGO
REPLACE
GND and HEGO SIG at the HEGO sensor
processor, except
connector.
for 3.8L Super
Is resistance greater than 10,000 ohms? Charged engine,
GO to Section 8. If
----.f..,..,~7""~~:'\
....,~
OK, then
HEGO SIGNAL REPLACE
POWER GROUND nil (( 'Ofn processor. RERUN
KEY POWER ~~U4~ Quick Test.
"'=K)
1- - FOR-2.3L.MA,2.9LMA,- - .~ 1 No ~ REPLACE HEGO
4.0L, 4.9L, AND 5.8L EFI: I sensor. REMOVE
l HEGO GROUND -'I I breakout box.
IL. SIG RTN (TRUCK ONLY) . JI RECONNECT
processor, RERUN
HEGO SENSOR CONNECTOR A13569-A Quick Test.

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
H181 ATTEMPT TO ELIMINATE CODE 41 ON

ENGINES WITH MAP SENSOR
Key off. Yes ~ REMOVE breakout box.

RECONNECT MAP
Breakout box installed. sensor vacuum line. If
Disconnect and plug MAP vacuum line. enrine, runs rough, GO
to 52 . All others
Connect processor to breakout box. REPLACE processor.
Reconnect HEGO sensor. RERUN Quick Test.
Start engine and run at approximately 2000 rpm

for 2 minutes. Allow engine to return to idle. No ~ REMOVE breakout box.
RECONNECT processor
Apply 10-14 in-Hg (3-46 kPa) vacuum to MAP and MAP sensor
sensor. vacuum line. HEGO
Rerun Engine Running Self-Test. sensor input OK.
Is Code 41 still present (Ignore all other For SEFI:

codes)? Fuel delivery is OK.
Problem is in an area
common to all
cylinders, Le. air/
vacuum leak, fuel
contamination, EGR.
CHECK MAP
frequency, etc.
For All Others:

GO to [ffiJ .
H191 ATTEMPT TO ELIMINATE CODE 41 ON

ENGINES WITH VANE AIR FLOW METER

Breakout box installed. REMOVE pencil from
Connect processor to breakout box. vane meter.
REINSTALL air cleaner.
Reconnect H/EGO .sensor. RERUN Quick Test.
Air cleaner removed, pe~cil inserted in Vane Air
Flow meter inlet. No ~ REMOVE breakout box.
Start engine and run at approximately 2000 rpm RECONNECT
for 2 minutes. processor. H/EGO
linpit circuit OK. GO to
Rerun Engine Running Self-Test. H1 .
Is Code 41 present?

ALL RIGHTS RESERVED
IFuel Control Pinpoint

Test
,H20 I
CHECK RESISTANCE OF HEATER ELEMENT
ON HEGO
Key off. Yes ~ GO to IH211 .

Disconnect HEGO.
No ~ REPLACE HEGO
DVOM on 200 ohm scale. sensor. RERUN Quick
Test.
Measure resistance between KPWR circuit and
PWR GND circuit at HEGO sensor connector.
Hot to warm resistance specification is 5.0 to 25.0
ohms.
Room temperature resistance specification is 2.0
to 5.0 ohms.
Is resistance within specification?
~
HEGOSIGNAL
POWER GROUND
KEY POWER
'-.;;:;;; IQ
1- - FOR2.i. MA,2.9L MA, - - ... 1
l 4.pL, 4.9L, AND 5.8L EFI: I
I HEGO GROUND I
IL. SIG RTN (TRUCK ONLY) ..JI

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
H21 I
CHECK FOR POWER AT HEGO
HARNESS CONNECTOR
Key on, engine off. Yes ~ RECONNECT HEGO

sensor. HEGO sensor
HEGO disconnected. system OK.
For SEFI:
Measure voltage between KEY POWER circuit and Fuel delivery is OK.
PWR GND circuit at the HEGO vehicle harness HEGO sensor may
connector.. have cooled prior to
Is yoltage greater than 10.5 Yolts? Test. If symptom
persists, problem is in
Jn1. an area common to all
~
~ HEGO SIGNAL
cylinders, Le. air/
n POWER GROUND
( .U~)
j1 KEY POWER vacuum leak, fuel
~'~ contamination, EGR,
I
"'-
r - - - - - - - - - - - - - - --,
FOR 2.3l MA, 2.9l MA, 4.0l, I
MAP. CHECK MAP
frequency, etc.
I 4.9l, AND 5.8l EFI: I SERVICE as necessary.
I HEGO GROUND I
:1_ _ _ _ _ _ _ _SIG RTN (TRUCK ONLY) : For All Others:
_ _ _ _ _ _ _ _ _ -J
GO to [!ff] .
HEGO VEHICLE
HARNESS CONNECTOR A9891-D
No ~ GO to IH221.
H221 CHECK CONTINUITY OF POWER GROUND

CIRCUIT
Key off, wait 10 seconds. Yes ~ SERVICE open in KEY

POWER circuit.
HEGO disconnected. RECONNECT HEGO
DVOM on 200 ohm scale. sensor. RERUN Quick
Test.
Measure resistance between PWR GND circuit at
the HEGO vehicle harness connector and battery No ~ SERVICE open in PWR
negative post. GND circuit.
Is resistance less than 5.0 ohms? RECONNECT HEGO
sensor. RERUN Quick
Test.

ALL RIGHTS RESERVED
Pinpoint
[Fuel Control H
Test
H23 SERVICE CODE 42/92:

FUEL CONTROL ALWAYS RICH; CHECK HEGO
SIGNAL FOR SHORT TO POWER
NOTE: For vehicles with dual HEGOs, code 42 Yes GO to.IH241.

refers to the right or rear # 1 HEGO
sensor. Code 92 refers to the left or No SERVIC~ HEGO circuit
front #2 HEGO sensor. . short to power.
RECONNECT HEGO
HEGO Engine Running codes 42 and 92 indicate sensor. RERUN Quick
the system is always rich. . Test.
Disconnect the appropriate HEGO sensor for Code
42/92.
Key on, engine off.
Measure voltage between HEGO SIG and PWR
GND at the HEGO vehicle harness connector.
.P-~--
........ HEGO SIGNAL
(~~--POWERGROUND
(-H-~-KEY POWER
r - - - - ... - - - - - - - - - ---,
, FOR 2.3L MA, 2.9L MA, 4.0L, J
I 4.9L, AND 5.8L EFI: I
I HEGO GROUND I
: SIG RTN (TRUCK ONLY) :
J_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ..J
HEGO VEHICLE
HARNESS CONNECTOR A9891D

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
H24 ICHECK HEGO SENSOR FOR SHORT TO

IGNITION RUN CIRCUIT
Key off. Yes ~ GO to IH2SI.

HEGO disconnected.
No ~ REPLACE HEGO
sensor. RERUN Quick
Measure resistance between KPWR circuit and Test.
HEGO SIG circuit at the HEGO sensor connector.
HEGO SIGNAL---~~~""""-~"",,
J/_~~
POWER GROUND ---'rrr.l"""({f-~-
KEY POWER ~~IJ4.
""'='0
1- - FOR-2.i MA,2.9L MA,- - -1
4.0L, 4.9L, AND 5.8L EFt: I
I HEGO GROUND I
IL.. SIG RTN (TRUCK ONLY) ..JI
H25 I ATIEMPT TO GENERATE CODE 41/91
Non-EEC areas could cause a Service Code 42/92. Yes ~ REMOVE jumper.
Check for:
For Engines With
- Fuel contaminated engine oil
MAP Sensor:
- Ignition caused misfire (fouled GO to IH261.
spark plug)
All Others:
- CANP problems
GO to IH281.
HEGO disconnected. No .. REMOVE jumper.
RECONNECT HEGO
Jumper HEGO SIG circuit at the HEGO vehicle
harness connector to battery negative post. sensor. DISCONNECT
processor 60 pin
Rerun Engine Running Self-Test. connector. Inspect for
Is Code 41/91 present? damaged or pushed
out pins, corrosion,
loose wires, etc.
If OK REPLACE
processor. RERUN
Quick Test.

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
~
, '
H26 I CHECK MAP SENSOR FOR VACUUM LEAK
NOTE: Due to the M~P sensor's large influence Yes ~ RELEASE vacuum. GO
on fuel control, there is a possibility that to IH271.
a Code 42/92 could be a result of a MAP
problem, even though a Code 22 is not No ~ REPLACE MAP sensor.
present. Therefore the next two Test REMOVE vacuum
Steps will verify proper vacuum to the pump. RECONNECT
MAP sensor and its ability to hold HEGO sensor. RERUN
vacuum. Quick Test.

Disconnect vacuum line from MAP sensor.
Connect a vacuum pump to the MAP sensor and
apply 18 in-Hg (60 kPa) vacuum to MAP sensor.
Does MAP sensor hold vacuum?
H271 CHECK FOR LOSS OF VACUUM TO MAP

SENSOR
Tee a vacuum gauge into the manifold vacuum Yes ~ INSPECT vacuum lines
line at the MAP sensor for leaks, holes,
disconnections, kinks,
Start the engine and let rpm stabilize. Note blockages, and proper,
vacuum level. routing. SERVICE as
necessary. REMOVE
Key off, wait 10 seconds. vacuum gauge and tee.
REMOVE vacuum gauge and tee and reconnect RECONNECT HEGO
vacuum line to MAP sensor sensor. RERUN Quick
Test.
Tee in vacuum gauge at a different source of
intake manifold vacuum and restart the engine.
Note vacuum level.
No ~ GO to IH2SI.
Does the vacuum level differ greater than 1
in-Hg?

ALL RIGHTS RESERVED
Pinpoint
IFuel Control Test
H
H28 HEGO SENSOR CHECK
Key off, wait 10 seconds. Yes ~ RECONNECT HEGO

HEGO sensor disconnected. sensor and vacuum
lines. HEGO sensor is
Connect DVOM to HEGO SIGNAL at the HEGO OK.
sensor connector and to battery negative post.
DVOM on 20 volt scale. For SEFI:
Fuel delivery is OK.
Create a vacuum leak to cause HEGO sensor to Problem is in an area
go lean. common to all
For 1.9L EFt: cylinders, i.e., air/
- Disconnect the manifold vacuum hose illustrated vacuum leak, fuel
below. contamination, EGR.
CHECK MAP
For All MA vehicles: frequency, etc.
- Disconnect any vacuum hose from the manifold SERVICE as necessary.
vacuum tree.
For All Others:
For all other applications: GO to [HI].
- Disconnect the PCV valve hose from the PCV
valve. No ~ REPLACE HEGO
Start engine and run at approximately 2000 rpm.. sensor. RECONNECT
Does the DVOM indicate less than 0.4 volts vacuum hoses. RERUN
within 30 seconds? Quick Test.
HEGO SIGNAL -------,~~

POWER GROUND -----".,.,~
KEY POWER --~~~
1- - F"0R2.iL. MA,2.9L MA,-

4.0L, 4.9L, AND 5.8L EFt:
1
I
I HEGO GROUND I
IL. SIG RTN (TRUCK ONLY) ...JI
HEGO SENSOR CONNECTOR A 13569-A
1.9L EFI
/
FRONT
OF
ENGINE
/
A1357o-A

ALL RIGHTS RESERVED
EEC-IV Pinpoint Test Pr~cedures. 17225
Pinpoint
IFuel Control Test
H
H291 CONTINUOUS. MEMORY CODE 41 OR 91/EXHAUST ODOR, SMOKE:
CODE 41/91 - Indicates. that a HEGO circuit has not switched during closed loop fuel
control.
NOTE: In this situation, Code 41 or 91 does not necessarily Indicate a lean condition.
Before attempting to service a Continuous -Memory Code 41 or 91, DIAGNOSE all other
driveability compraints first (e.g., rough idle, misses, etc.) using Diagnosis by Symptom.
Symptom:
Exhaust odor, smoke is possible to appear without code 41/91, it is an intermittent fault and
could be due to loose HEGO SIG or HEGO GND connection or poor HEGO harness insulation
near the exhaust manifold. The processor thinks the system is lean and therefore leads to an
over-rich fuel condition.
Some areas to check are:
HEGO SIG and GND conn~ctions.
HEGO harness insulation near the exhaust manifold.
Unmetered Air (vacuum leak~/intake air leaks):
Canister purge system.
PCV system.
- . ~ngine s.ealing.
Crimped fuel lines.
Plugged fuel filter.
Fouled fuel injectors.
Air leaks between mass air flow sensor and air outlet tube to throttle body.
HEGO Fuel Fouled:
Whenever an over-rich fuel condition has been experienced (fuel fouled spark plugs), make a
thorough check of the ignition system. If a HEGO sensor is suspected of being fuel fouled
(low output or slow response), run the vehicle at sustained high speed (within legal limits)
followed b~ a few hard accels. This will burn off the HEGO contamination and restore
proper HEGO operation.
Ignition System:
If engine is always in DEfAULT spark (base timing) refer to Quick Test Step 14.0 I.
Improper Fueling:
lead fouled HEGO sensor.
Fuel Pressure:
Perform Pinpoint Test Steps ffijJ and IH21 .
TP Sensor:
Turn key to RUN position. While moving throttle slowly toward wide-open position, measure
voltage between Test Pins 47 and 46 at the breakout box. If the voltage does not increase
with the increase of throttle opening, replace TP sensor or linkage as necessary.
If at this~int the driveability concern is still present, perform Pinpoint Test Steps IH31
through ~. .

ALL RIGHTS RESERVED
17226 EE~IV Pinpoint Test Procedures
Pinpoint
IFuel Control Test
H
H301 CONTINUOUS MEMORY CODE 41, 42, 43, 65, 85, OR 86:
Code 41 - -HEGO indicated the fuel system was lean for more than 15 seconds when the
fuel system should have been in closed loop fuel control.
Code 42 HEGO indicated the fuel system was rich for more than 15 seconds when the
fu~1
system should have been in closed loop fuel control.
Code 43 HEGO indicated the fuel system was lean at WOT for more than 3 seconds.
Code 65 Never went to closed loop fuel control on HEGO switching.
Code 85 Adaptive fuel has corrected an excessive rich condition. (Adaptive fuel made the
fuel system leaner.)
Code 86 - Adaptive fuel has corrected an excessive lean condition. (Adaptive fuel made the
fuel system richer.)
Before attempting to service a Continuous Memory Code 41, 42, 43, 65, 85, or 86,
DIAGNOSE all other driveability complaints first. Examples: rough idle, misses, etc. using
Whenever an over-rich fuel condition has been experienced (fuel fouled spark plugs), make a
thorough check of the ignition system. If a HEGO sensor is suspected of being fuel fouled
(low output or slow response), after the vehicle service, run the vehicle at sustained high
speed (within legal limits) followed by a few hard accels. This will burn off the HEGO
contamination and restore proper HEGO operation.
The fuel Service Code may help to isolate the cause of the fuel control problem.' Some
areas to check are:
For Code 41:
Intermittent HEGO circuit (SIG or GND).
If Code 65 is also present, service faulty HEGO circuit (SIG or GND).
If Code 43 is also present, service Code 43 first.
Vane Air Flow meter indicates low air flow. Check for vacuum leaks, intake air leaks, or a
sticking vane caused by contamination or frost.
Low fuel pressure at WOT.
Low-pressure fuel pump.
Restricted fuel supply (crimped fuel lines or plugged fuel filter or screen at the Fuel
Pressure Regulator).
Low fuel flow at WOT with correct fuel pressure.
Clogged fuel injectors.
Low battery voltage less than 11 volts.

ALL RIGHTS RESERVED
Pinpoint
.1 Fuel Control H
Test
I
H30 (CONTINUED)
F~r Code 42:

Intermittant HEGO circuit (SIGNAL or GROUND).
Air Flow indicated by the 'Vane Air Flow Meter is greater than the actual air flow (causing
more fuel to be delivered than necessary). Check for high Vane Air Flow meter voltage
output due to a sticking vane caused by contamination.
Excessive fuel pressure. Check for fuel pressure regulator vacuum line disconnected or .
kinked fuel return line.
Excessive fuel flow. Check for damaged or stuck open fuel injector(s).
For Both Codes 41 and 42:
Intermittant HEGO circuit (SIGNAL or GROUND).
Sticking Vane Air Flow Meter vane due to contamination.
Contaminated HEGO sensor (lead or silicone fouled).
Improper fuel pressure. Check fuel pump and fuel pressure regulator~
For Code 43:

Low fuel pressure at WOT.
-. Low pressure fuel pump.
- Restricted fuel supply (crimped fuel lines or plugged filter).
Low fuel flow at WOT with correct fuel pressure.
- Clogged fuel injectors..
- Low battery voltage less than 11 volts.
For Code 65:
Check for faulty HEGO circuit (SIGNAL or GROUND).
For Code 85:
If Code 42 is, also present, service Code 42 first.
Excessive fuel pressure. Check for fuel pressure regulator vacuum line disconnected or
kinked fuel return line.
Excessive fuel flow. Check for damaged fuel injector pintle or injectors stuck open.
For Code 86:
If Code 41 is also present, service Code 41 first.
Low fuel pressure
Low pressure fuel pump.
- Restricted fuel supply (crimped fuel lines) screen at Fuel Pressure Regulator or plugged
filter.
Low fuel flow with correct fuel pressure
Clogged fuel injectors.
Low battery (fuel injector voltage less than 11 volts).

ALL RIGHTS RESERVED
Pinpoint
IFuel Pump Circuit Test
J
INote I
You should enter this Pinpoint Test only when a Service Code 87, 95 or 96 is received
during Quick Test or if you have been directed here from Pinpoint Test 00 or
IRemember I
Fuel Pump Relay (-9345-)
Inertia Switch (-9341-)
Harness circuits: BAn (+), VPWR, F.P., GND and Power-To-Pump(s)

1.9L CFI, 1.9L EFI, 2.3L HSC
FUEL PUMP
TO SELF-TEST RELAY
CONNECTOR VEHICLE HARNESS TEST PIN 22
CONNECTOR
TEST PIN 22 <:> FUEL PUMP-.....- - - - - t - o TO IGNITION
w-~-u START/RUN~-~i+-+-'
TEST PIN 8 <:}-PKlBK FPM -------+-U CIRCUIT
t
POWERTOPUMP Y
PKlBK TO
TEST
BATT (+)
PIN 8
TO
TO IGNITION BATT (+)
TO
START/RUN TO FUEL
CIRCUIT FUEL PUMP
PUMP
A11532C
Test Pin 22 Fuel Pump

1.9L CFI T/LG
1.9L EFt
2.3L HSC OILS

ALL RIGHTS RESERVED
Pinpoint
J

1.9L MA SEFI, 2.3L MA EFI, 5.0L SEFI MA MUSTANG, 2.3L TRUCK,
2.9L TRUCK, 3.0L EFI TRUCK, 4.0L EFI
TO SELF-TEST
CONNECTOR FUEL PUMP
RELAY
VEHICLE HARNESS
CONNECTOR
TEST PIN 22 ~ T/LG - - FUEL PUMP--oI-----+oou TEST PIN 22
TEST PIN 8 .,~_ _-+-- F P M - - - - - - -.......-u

TEST PIN 19 TO
(1.9L MA, 5.0L MA) VPWR~--*+--"!--' I
POWER-TOPUMP
TEST PIN 37 .~.--..

TO
BAIT + TO
TEST PIN 57 BAIT +
TO EEC FUEL
POWER PUMP TO
RELAY FUEL
(VPWR) PUMP
~
INERTIA SWITCH LOCATION - MUSTANG NOTE: FOR 1.9L MA SEFI POWERTOPUMP
2 INERTIA SWITCH LOCATION -1.9L MA SEFI . AND INERTIA SWITCH CIRCUITS ARE DOUBLED
3 INERTIA SWITCH LOCATION - ALL OTHERS (2-WIRES EACH) A11533.C
Test Pin 8 (19) FPM POWERTOPUMP Circuit

2.3L Truck 2.3L Truck
O/LB
2.9L Truck O/LB 4.0L Ranger, Bronco II
4.0L Ranger, Bronco II
All Others PK/BK
All Others PK/BK
BATT(+) Test Pin 37/57 VPWR
Application Wire Color'. Application Wire Color
2.3L Truck 1.9L MA SEFI W/R
2.9l Truck BK/Y
All Others R
4.0l Ranger, Brpnco II
3.0L EFI Truck . y.
4.0L Aerostar
5.0L SEFI MA
O/LB
2.3L MA EFI Car
1.9L MA SEFI W/GR

ALL RIGHTS RESERVED
Pinpoint
J

3.8L SEFI RWD, 3.8L SEFI se, 4.9l EFI, 5.0l EFI, 5.8l EFI, 7.5L EFI
TO SELF-
TEST CONNECTOR FUEL PUMP
RELAY
VEHICLE HARNESS
CONNECTOR
TEST PIN 22
TEST PIN 2 2 0 - - - FUEL PUMP -----4t-----+-u
TEST PIN 8 0--FPM~...-.--a~----~-4J TO

(TEST PIN 19 FOR 3.8l SC) <D
POWER-TO-PUMP VPWR ~---4to........!--' I
TEST PIN 50 FOR 3.8L

SEFIRWO)
TEST PIN 37 G>-t' VPWR TO
TEST PIN 57 &.J TO BATI+
BATI+ FPM
TO
TEST
TO EEC FUEL PIN
POWER PUMP
TO
RELAY
FUEL
(VPWR)
PUMP
G) INERTIA SWITCH LOCATION-THUNDERBIRD/COUGAR

(2) INERTIA SWITCH LOCATION-FSERIES. E-SERIES. BRONCO
A11534-C
TEST PIN 8 (19, 50)

POWERTOPUMP Circuit BAn(+) At Relay
F-Series F-Series
DG/Y
Bronco E-Series Y
Bronco
E-Series OILS
Thunderbird/Cougar PK/BK
Thunderbird/Cougar BK/Y .
VPWR at Relay Test Pin 22 FP

F-Saries F-Series
LS/O
E-Series R Bronco
Bronco
All Others T/LG
Thunderbird/Cougar W

ALL RIGHTS RESERVED
EEe-IV Pinpoint Test Procedures 17-231
IFuel Pump Circuit Pinpoint

.Test
J

2.3l OHC EFI, CAR, S.Ol SEFI MARK VII
TO SELF-TEST FUEL PUMP
CONNECTOR RELAY VEHICLE
HARNESS CONNECTOR
TEST PIN 22
T/LG
TEST PIN 22 0~--- FUEL PUMP-R-......-+-...f-oU
TO
VPWR~-""""",~~I
'. TEST PIN 37 0-t- VPWR

TEST PIN 57 G)-1 TO
TO
TO EEC TO FUEL
BATT +
POWER FUEL PUMP
RELAY PUMP
(VPWR)
G) INERTIA SWITCH LOCATION - MUSTANG

INERTIA SWITCH LOCATION - MARK VII
A11535-C
BATT(+) At Relay
Mustang OILS
Mark VII R

ALL RIGHTS RESERVED
Pinpoint
J
5.0l SEFI TOWN CAR, CROWN VICTORIA/GRAND MARQUIS

S.Ol SEFI MA TOWN CAR, CROWN VICTORIA/GRAND MARQUIS
TEST PIN 37 0 - - - - - - - - R
TEST PIN 57 0~------R--~-VPWR
TO
BATT (+)
BATT (+)
o DO
o
i RELAY BLOCK
VEHICLE HARNESS
CONNECTOR
u....I~_~_ _~'--_ _ -+- ...... (LOCATED ON
WAC VACUUM
RELAY RESERVOIR)
TEST PIN 22
TEST PIN 22 0- T/LG - FUEL PUMP

TO L.-~'n ... VlI FUEL
VPWR ~----4ot+--+-"'1 PUMP
SELF-TEST r-1t1~.1J RELAY
CONNECTOR
POWER
-TO-
PUMP
.---------------------------------
I <:>
TEST PIN 19 FPM - - - - - - - - -__
TO
FUEL
PUMP
:: 5.0L SEFI TOWN CAR (
"
INERTIA
I 5.0L SEFI MA TOWN CAR, CROWN VICTORIA! I SWITCH
:1 GRAND MARQUIS
~ .J:
TO
FUEL
PUMP A13563A
Test Pin 19 FPM

Crown Victoria/Grand
0
Marquis
Town Car PK/BK

ALL RIGHTS RESERVED
Pinpoint
J

2.9L EFI SCORPIO
FUEL PUMP RELAY
(RELAY A)
TEST PIN 22
TEST PIN 22 0 - - - - - - F U E L PUMP---
FUEL
BLIR
TO PUMP
TEST PIN 37 ~ VPWR - BK/R VPWR RELAY
~~~ (A)
TEST PIN 57 ~
c::::J-I~ BATT(+) TO
FUEL
BKIR PUMP
POWER
-TO-
PUMPS
~~~~20A, INSIDE
INERTIA
SWITCH & GLOVE COM,PARTMEN.T)
~
TO FUEL
PUMP
A13564-A

ALL RIGHTS RESERVED
Pinpoint
J
J1 NO FUEL PUMP PRESSURE:

CHECK FOR FUEL PUMP ELECTRICAL
OPERATION
To check if fuel pump runs, turn key from Ott to Yes ~ GO to Section 11. Also
Run position, repeat several times. (Do not turn to REFER to Fuel/Engine
start position.) Shop Manual Group.
Does fuel pump run briefly each time the key
is turned to RUN position?
No ~ GO to IJ21.
J2 CHECK FOR VPWR TO PROCESSOR
Key off. Yes ~ For 2.9L EFI:

GO to IJ3\.
DVOM on 20 volt scale. For all others:
GO to IJSI.
Key on, engine off.
Measure voltage between Test Pin 37 and Test No ~ GO to OOJ.
Pin 40 at the breakout box and between Test Pin
57 and Test Pin 60 at the breakout box.
Are both Yoltages greater than 10.5 Yolts?
J3 CHECK CONTINUITY BETWEEN FUEL PUMP

RELAY AND FUEL CIRCUIT FUSE
Key off. Yes ~ GO to IJ41.

No ~ SERVICE open
Disconnect fuel pump relay. between fuel pump
Disconnect fuel pump circuit fuse (# 30). relay and fuel pump
circuit fuse (# 30).
RECONNECT all
Measure resistance between Power-To-Pump components. RE-
circuit at fuel pump relay vehicle harness EVALUATE symptom.
connector and relay side of fuse connector.
~
TEST
VPWR PIN 22
POWER
BATT ( + ) -TO-
PUMP
FUEL PUMP RELAY
. VEHICLE HARNESS CONNECTOR A 13565-A

ALL RIGHTS RESERVED
Pinpoint
IFuel Pump Circuit
Test
J
J4 ICHECK FOR VOLTAGE TO POWER-TO-PUMP

CIRCUIT
Key off. Ves ~ RECONNECT Fuse. Go

to Section 11 for open
Breakout box installed, processor connected. in Power-To-Pump
Fuel pump circuit fuse (# 30) disconnected. circuit, fuel pump
ground, .open in pump,
Reconnect fuel pump relay. etc. Also, REFER to
Fuel/Engine Shop
DVOM on 20 volt scale. Manual Group.
Measure voltage between relay side of fuel pump
circuit fuse connector and chassis ground while
cranking engine.
No ~ RECONNECT fuse, GO
to IJ61.
Is Yoltage greater than 8.0 Yolts during crank?
J5 ICHECK FOR VOLTAGE TO POWER-TO-

PUMP(S) CIRCUIT
Key on, engine off. Ves ~ GO to Section 11 for

open in Power-To-
Breakout box installed, processor connected. Pump circuit, fuel pump
DVOM on 20 volt scale. GND, open in pump,
etc. Also REFER to
Measure voltage between chassis ground and Fuel/Engine Shop
Power-To-Pump circuit at fuel pump relay while Manual Group.
cranking engine.
Is yoltage greater than 8.0 YOIts during crank? No ~ GO to \J61.
J6 I CHECK FOR BATT+ TO FUEL PUMP RELAV
Key on, engine off. Ves ~ 1.9L ~FI:

GO to IJ71.
Breakout box installed (if applicable), processor
connected. ALL OTHERS,
DVOM on 20 volt scale. GO to QIT].
Measure voltage between chassis ground and
BATT(+) at the fuel pump relay. No ~ SERVICE open in
...
BATT(+) between fuel
Is Yoltage greater than 10.5 Yolts? pump relay and battery
positive post (for relay
block applications,
,
between fuel pump
relay and EEC power
relay). REMOVE
breakout box.
RECONNECT
processor. RERUN
Quick Test.

ALL RIGHTS RESERVED
Pinpoint
J
J7 I CHECK FOR VPWR TO FUEL PUMP RELAY
Service Code 87 indicates a fuel pump primary Yes ~ GO to IJS\.

circuit failure.
. Possible causes are: No ~ VERIFY inertia switch
- Inertia switch not reset or electrically open (if in is reset to On. If
primary circuit). switch will not reset,
REPLACE switch. If
- Op~n or shorted circuit. OK,
- Faulty fuel pump relay. For 1.9L EFI, 1.9L CFI
- Faulty processor. and 2.3L HSC:
Key on, engine off. SERVICE open
DVOM on 20 volt scale. between ignition switch
start/run circuit and
Measure voltage between chassis ground and fuel pump relay.
VPWR circuit (Ignition start/run circuit for 1.9L
EFI, 1.9L CFI and 2.3L HSC) at the fuel pump All others:
relay. SERVICE open in
Is Yoltage greater than 10.5 Yolts? VPWR circuit between
the EEC power relay
and the fuel pump
relay.
RERUN Quick Test.
J8 I CHECK FUEL PUMP CIRCUIT CONTINUITY
Key off, wait 10 seconds: Yes .~ GO to IJ91.

Install breakout box, leave processor disconnected. RECONNECT
processor. RERUN
DVOM on 200 ohm scale. Qui~k Test.
Measure resistance between fuel pump circuit at
the fuel pump relay and Test Pin 22 at the
breakout box.
J9 ICHECK
POWER
FUEL PUMP CIRCUIT FOR SHORT TO
Key off.. Yes ~ GO to IJ1ol.

Disconnect fuel pump relay. No ~ SERVICE short circuit.
RECONNECT all
DVOM on 20 volt scale. components. ATTEMPT
Key on, engine off. to start vehicle. If
Measure voltage between Test Pin 22 at the vehicle fails to start,
breakout box and battery negative post. REPLACE processor.
RERUN Quick Test.
Is yoltage less than 1.0 Yolt?

ALL RIGHTS RESERVED

Test
J
J10 ICHECK FUEL PUMP CIRCUIT FOR SHORT TO

GROUND
Key off, wait 10 seconds. Yes ~ RECONNECT fuel

Breakout box installed, processor disconnected. QI1f
J11.
relay. GO to
.
Fuel pump relay disconnected.
Piris 40 and 60 at the breakout box. REMOVE breakout box.
RECONNECT all
Is resistance greater than 10,000 ohms? components. RERUN
Quick Test.
J11 ICHEyK FOR VOLTAGE AT POWER-TO-PUMP(S)
CIRCUIT .

Connect jumper wire from Test Pin 22 to Test Pin R,ERUN Quick Test.
40 or 60 at the breakout box.
DVOM on 20 volt scale. No ~ REPLACE fuel pump
Key on, engine off. relay. REMOVE
breakout box.
Measure voltage between chassis ground and RECONNECT
Power-To-Pump circuit at fuel pump relay. processor. RERUN
Is v~ltage greater than 10.5 volts? Quick Test.
J20 ISERVICE CODE 95:

DOES ENGINE START
Service Code 95 indicates that one of the following Yes ~ GO to IJ211.
has occurred:
No Starts: No ~ GO to IJ2SI.
- Inertia switch not reset or electrically open (if in
secondary circuit).
#
- Open circuit in or between the fuel pump and

FPM circuit connection to the Power-To-Pump
circuit. .
- Poor fuel pump ground
Vehicle Starts:
- Fuel pump secondary circuit short to power
- Fuel pump relay contacts always closed
- Open in FPM circuit between processor and
connection to the Power-To-Pump circuit. "
- For 1.9L EFI, fuel pump circuit (pin 22) short to
ground.
- Faulty processor
Does the engine start?
J21 I VERIFY THAT FUEL PUMP IS OFF
Key off. Yes ~ GO to IJ231.

Listen for motor noise from fuel pump.
Is fuel pump off? No ~ GO to IJ221.

ALL RIGHTS RESERVED
Pinpoint
J.
J221 CHECK FOR FUEL PUMP RELAY

ALWAYS CLOSED
Key off. Yes ~ REPLACE fuel pump

relay. RERUN Quick
Locate and disconnect fuel pump relay. Test.
Does fuel pump shut off when relay is
disconnected? No ~ SERVICE short to
power in POWER-TO-
PUMP/FPM circuit. (For
5.0L, except Mustang,
also CHECK fuel pump
prime plug circuit.
REFER to Schematic).
RERUN Quick Test.
J23 I CHECK FPM CIRCUIT CONTINUITY

GO to IJ241.
for damaged or pushed out pins, corrosion, loose For all others:
wires, etc. Service as necessary. REPLACE processor.
Install breakout box, leave processor disconnected. RECONNECT fuel
Disconnect fuel pump relay. pump relay. RERUN
Quick Test.
Measure resistance between Test Pin' 8 (Test Pin No ~ SERVICE open circuit.
19 for 5.0L, 1.9L SEFI, 3.8L SC; Test Pin 50 for REMOVE breakout box.
3.8L SEFI RWD) at the breakout box and Power- RECONNECT all
To-Pump circuit at the fuel pump relay vehicle components. RERUN
~~
POWER 0 OcD
-~ BATT(+) POWER
PUMP -T~
BATT ( + ) PUMP
FUEL PUMP RELAY VEHICLE HARNESS

CONNECTOR (USE APPLICABLE DRAWING)
A9196-B

ALL RIGHTS RESERVED
Pinpoint
J
J24 rCHECK FUEL PUMP PRIMARY CIRCUIT FOR

SHORT TO GROUND

Breakout box installed, processor disconnected. RECONNECT fuel
Fuel' pump relay disconnected. pump relay. RERUN
Quick Test.
Pin 40 at the breakout box. REMOVE breakout box.
RECONNECT all
Is resistance greater than 10,000 ohms? components. RERUN
Quick Test.
J25 I CHECK INERTIA SWITCH
Key off, wait 10 seconds. Yes ~ RECONNECT inertia

switch. GO to IJ261 .
Locate and disconnect fuel pump inertia switch
(verify that switch is reset).
No ~ REPLACE or RESET
DVOM on 200 ohm scale. inertia switch. RERUN
Quick Test.
Measure resistance of the fuel pump inertia
switch. (For 1.9L MA SEFI, measure between
GND pin and FP pin).
FP-Q-METER
PASSIVE C/U
GND
1.9L MA SEFI
INERTIA SWITCH
A13566-A

ALL RIGHTS RESERVED
Pinpoint
IFuel Pump Circuit
Test
J
J26 I
TEST STEP
CHECK FOR CONTINUITY BETWEEN

FPM CIRCUIT AND GROUND
RESULT
ACTION TO TAKE
Key off.
Fuel pump relay disconnected.
Yes
REPLACE processor.
RECONNECT fuel
pump relay. RERUN
Quick Test.
19 for 5.0L, 1.9L SEFI, 3.8L SIC; Test Pin 50 for
3.8L SEFI RWD) at the breakout box and battery
negative post.
No
RECONNECT all
components. GO to
Fuel/Engine Shop
Manual Group, Electric
Is resistance less than 10.0 ohms? Fuel Pump, for open in
Power-To-Pump circuit,
poor fuel pump ground,
open in fuel pump, etc.
J30 ICHECK
SERVICE CODE 96:
FOR BATT(+) TO FUEL PUMP RELAY
Service Code 96 indicates a fuel pump secondary

circuit failure between the BATT(+) supply and the
Yes
GO to IJ311.
FPM connection to the Power-To-Pump circuit.

- Open circuit.
No
SERVICE open in
BATI(+) circuit.
RERUN Quick Test.
- Faulty fuel pump relay.

- Faulty processor.
Locate fuel pump relay.
Measure voltage between BATI(+) circuit at the
fuel pump relay and battery negative post.
Is Yoltage greater than 10.5 YOIts?
~~
POWER D . OeD
-10- . BATT ( + ) POWER
PUMP -TO-
BATI(+) PUMP
FUEL PUMP RELAY VEHICLE HARNESS
CONNECTOR (USE APPLICABLE DRAWING)
A9196-B

ALL RIGHTS RESERVED
Pinpoint
J
J31 CHECK FOR VOLTAGE AT POWER-TO-PUMP

CIRCUIT TO VERIFY FUEL PUMP RELAY
OPERATION
Key off. Yes ~ For 3.8L SEFI RWD,

3.8L SEFI SC, 5.0L
DVOM on 20 volt scale. (except Mustang),
Connect DVOM between Power-To-Pump circuit at 4.9L EFI, 5.0L EFI,
the fuel pump relay and battery negative post. 5.8L EFI and 7.5L EFI:
GO to IJ321.
Observe DVOM as you activate fuel pump relay
(turn key to run for 1 second, then to off for .10 For all others:
seconds. Repeat 5 times). REPLACE processor.
RERUN Quick Test.
Does Yoltage measure greater than 10.5 Yolts
for about 1 second after key is turned to RUN
position during test?
No ~ DISCONNECT fuel
pump relay. INSPECT
for damaged pins,
corrosion, loose wires,
etc. If OK, REPLACE
fuel pump relay.
RERUN Quick Test.
J32 CHECK POWER-TO-PUMP CIRCUIT

CONTINUITY

Disconnect processor 60 pin connector. Inspect RECONNECT fuel
for damaged or pushed out pins, corrosion, loose pump relay. RERUN
Disconnect fuel pump relay.
Power-To-Pump circuit
DVOM on 200 ohm scale. between FPM splice
and fuel pump relay.
Measure resistance between Test Pin 8 (Test Pin REFER to schematic.
19 for 5.0L, 3.8L SC and Test Pin 50 for 3.8L REMOVE breakout box..
SEFI RWD) at the breakout box and Power-To- RECONNECT all
Pump circuit at the fuel pump relay vehicle components. RERUN

ALL RIGHTS RESERVED
Pinpoint
J
J90 ICONTINUOUS MEMORY CODE 95:

CHECK EEC-IV HARNESS
A Continuous Memory Code 95 indicates that one Yes ~ ISOLATE fault and
of the following intermittent conditions has occurred: SERVICE as necessary.
CLEAR Continuous
- Open circuit in or between the fuel pump and Memory (REFER to
FPM circuit at the processor (see schematic). Quick Test Appendix).
RERUN Quick Test.
- Poor fuel pump ground.
- FPM or Power-To-Pump circuit short to power. No ~ GO to IJ911.
- Fuel pump relay contacts stuck closed.
- Fuel pump circuit activated when processor
expected circuit to be off (Le. fuel system test
or prime procedure).
Start engine~
Check for engine stall/stumble while performing
the following (also, if possible, listen for fuel pump
turning off.)
- Shake, wiggle, bend the Power-To-Pump
circuit between the Power-To-Pump pin at the
fuel pump relay and the fuel pump.
- Shake, wiggle, bend the fuel pump ground
circuit from the fuel pump to ground.
- Lightly tap the fuel pump to simulate road
shock.
- For vehicles with the inertia switch in the
Power-To-Pump circuit (refer to schematic),
lightly tap inertia switch to simulate road
shock.
Key off.
Inspect the fuel pump vehicle harness connector
and the fuel pump ground for corrosion, damaged
pins, etc.
Is fault indicated/found?

ALL RIGHTS RESERVED

Test
J
J91 I CHECK FPM CIRCUIT
Key off. Yes ~ ISOLATE fault and

for damaged or pushed out pins, corrosion, loose CLEAR Continuous
wires, etc. Service as necessary. Memory (REFER to
Install breakout box, leave processor disconnected. Quick Test Appendix).
RERUN Quick Test.
Key on, engine off.
Connect a TEST LAMP between Test Pin 8 (Test No ~ GO to IJ921.
Pin 19 for 5.0L, 1.9L SEFI, 3.8L SC; Test Pin 50
for 3.8L SEFI RWD.) and Test Pin 37 at the
breakout box.
Observe test lamp for an indication of a fault
while performing the following (The light will go
out when a fault is found, indicating an open):
- Shake, wiggle, bend the fuel pump monitor
circuit between the fuel pump relay (or splice
if applicable, see schematic) and the
. proces~or.
Is fault indicated?
J92 I CHECK FOR SHORTS TO POWER
Key on, engine off. . Yes ~ ISOLATE fault and

Breakout box installed. processor disconnected. REMOVE breakout box.
Connect a TEST LAMP between Test Pin 8 (Test RECONNECT
Pin 19 for 5.0L, 1.9L SEFI, 3.8L SC; Test Pin 50 processor. CLEAR
for 3.8L SEFI RWD) and Test Pin 40. Continuous Memory
Observe test lamp for an indication of a fault Appendix). RERUN
while performing the following (The light will turn Quick Test.
on when a fault is detected, indicating a short to
power. Also, if possible, listen for fuel pump
turning on.):
- Shake, wiggle, bend the fuel pump monitor this time. For further
circuit and Power-To-Pump circuit, especially dia~osis using the
where they may be in the vicinity of a power EE -IV Monitor Box,
REFER to Section 18
circuit. EEC-IV Monitor Box:
Lightly tap the fuel pump relay (to simulate road Intermittent Fault
shock). Diagnosis.
Is fault indicated? All others, CLEAR
Continuous Memory
Appendix). RERUN
Quick Test.

ALL RIGHTS RESERVED
Pinpoint
J
I
J93 ICONTINUOUS MEMORY CODE 96:

CHECK FOR CONTINUOUS MEMORY CODE 87
Is Continuous Memory Code 87 also present? Yes ~ GO to IJ9SI.

No ~ GO to IJ941.
J94 I CHECK EEC-IV HARNESS
A Continuous Memory Code 96, without the Yes ~ ISOLATE fault and
presence of a Continuous Memory Code 87, SERVICE as necessary.
indicates that during vehicle operation, one of the CLEAR Continuous
following has occurred: Memory (REFER to
- Open in the BATT(+) circuit between BATT(+) RERUN Quick Test.
and the fuel pump relay. .
- Fuel pump relay contacts opened. No ~ For 1.9L EFI:
GO to IJ9SI.
- Open in the Power-To-Pump circuit from the
fuel pump relay to the FPM splice, if applicable For all others:
(see schematic). Unable to duplicate
Start engine. this time. For further
Check for engine stall/stumble while performing diaenosis using the
the following (also, if possible, listen for fuel pump EE -IV Monitor Box,
turning off): REFER to Section 18
EEC-IV Monitor Box:
- Shake, wiggle, bend the BATT(+) circuit from Intermittent Fault
BATT(+) to the fuel pump relay. Diagnosis.
- Lightly tap the fuel pump relay (to simulate All others, CLEAR
road shock). Continuous Memory
- Shake, wiggle, bend the Power-To-Pump
Appendix). RERUN
circuit from the fuel pump relay to the FPM Quick Test.
splice, if applicable (See schematic).
Key off.
Inspect the fuel pump relay connectors and
BATT(+) connector terminal for corrosion,
damaged pins, etc.

ALL RIGHTS RESERVED
Pinpoint
J
J95 ICHECK
CONTINUOUS MEMORY CODE 87:
EEC-IV HARNESS .
A Continuous Memory Code 87 indicates that a fuel Yes ~ ISOLATE fault and
pump primary circuit failure has occurred during SERVICE as necessary.
vehicle operation. Possible causes are: CLEAR Continuous
Memory (REFER to
- Open in VPWR circuit between the EEC power Quick Test Appendix).
relay and the fuel pump relay. RERUN Quick Test.
- Open coil in fuel pump relay.
- Open in fuel pump circuit (Pin 22). and/or identify fault at
- Faulty inertia switch. this time. For further
dia~nosis using the
Start engine. EE -IV Monitor Box,
REFER to Section 18
Check for engine stall/stumble while performing EEC-IV Monitor Box:
the following (also, if possible, listen for fuel pump IntermIttent Fault
turning off): Diagnosis.
- Shake, wiggle, bend the VPWR circuit
All others, CLEAR
between the EEC power relay and the fuel Continuous Memory
pump relay. For vehicles with the inertia (REFER to Quick Test
switch in the VPWR circuit (refer to Appendix). RERUN
schematic), lightly tap the inertia switch to Quick Test.
simulate road shock.
- Shake, wiggle, bend the EEC-IV vehicle
harness fuel pump circuit (Test Pin 22)
between the processor and the fuel pump
relay.
- Lightly tap the fuel pump relay to simulate
road shock.
Key off.
Inspect the processor 60 pin connector and the
fuel pump relay connectors for corrosion,
damaged pins, etc.

ALL RIGHTS RESERVED
Pinpoint
IEGR On/Off Control Test
KA
INote I
You should enter this Pinpoint Test only when you have been directed here from
Diagndsis By Symptom.
IRemember I
may be at fault:
Air or Vacuum Leaks

EGA Flow Restrictions
EGA Valve
Harness circuits: EGR and VPWR
EGR Solenoid (-90474:)
Presence of Manifold Vacuum

*TEST PIN 3 5 ( ! ) - - -........
y----EGR -----+:oL..J ] ~
_ -......._L..I ""\
EGR
SOLENOID
VEHICLE
HARNESS
CONNECTOR
TEST PIN 37 (!)--....;R;";",,..---VPWR---__
rEST PIN 57 (!) R VPWR - - - -


ALL RIGHTS RESERVED
EEe-IV Pinpoint Test Procedures 17247 .
Pinpoint
KA
KA1 IENTER OUTPUT STATE CHECK (REFER TO

QUICK TEST APPENDIX)
Possible causes: Yes ~ REMAIN in Output

State Check.
- Faulty EGR On/Off control solenoid. GO to IKA21.
- Faulty EGR solenoid.
- Faulty EGR vent solenoid.
No ~ DEPRESS throttle to
WOT and release. If
- Faulty EVP sensor. STO voltage does not
go high, leave
- Faulty wire harness. equipment hooked up
- Faulty processor. and GO to~oint
Test Step QC1 .
- Manifold vacuum line blockage and/or leak.
NOTE: Do not use STAR tester for this step, use
a VOM/DVOM.
Disconnect electrical connector on the speed
control servo, if equipped.
Connect DVOM negative test lead to STO at the
Self-Test connector and positive test le~d to
battery positive.
Jumper STI to SIG RTN at the Self-Test
connector.
Rerun Key On Engine Off Self-Test until the
completion of the Continuous Test Codes.
DVOM will indicate less than 1.0 volts.
Depress and release the throttle.
Did DVOM reading change to a high voltage
reading?
KA21 CHECK EGR SOLENOID ELECTRICAL

OPERATION
Disconnect EGR solenoid. Yes ~ GO to IKA31.

No ~ REMOVE STI jumper.
Connect DVOM positive test lead to VPWR circuit GO to IKASI.
on EGR solenoid and negative test lead to EGR
output circuit.
While observing DVOM, depress and release the
throttle several times to .cycle output on and off.
Does EGR output cycle on and off?

ALL RIGHTS RESERVED
'17-248 EEe-IV Pinpoint Test Procedures
Pinpoint
KA
KA31 CHECK EGR SOLENOID FOR VACUUM

CYCLING
Reconnect EGR solenoid. Yes ~ GO to IKA41.

Install vacuum pump to the solenoid vacuum
supply port and install a vacuum gauge to the No ~ REPLACE solenoid.
output port. Apply 6 in-Hg minimum. RERUN Quick Test.
While cycling outputs on and off (by depressing

and releasing throttle) observe the vacuum gage
at the output.
NOTE: Maintain vacuum at source.
Does output port vacuum cycle on and off?
KA41 CHECK MANIFOLD VACUUM LINES FOR

BLOCKAGE OR LEAKS
Vacuum lines disconnected at solenoid. Yes ~ EEC-IV system OK. GO

to Section 6, EGR
Start engine. Systems Diagnosis.
Check for vacuum.
Is vacuum present?
No ~ SERVICE vacuum
source blockage or
leak. RERUN Quick
Test.
KA5 I MEASURE EGR SOLENOID RESISTANCE
Key off, wait 10 seconds. Yes ~ GO to IKA61.

EGR solenoid disconnected.
No ~ REPLACE EGR
Measure resistance between EGR circuit and Test.
VPWR circuit at the EGR solenoid.
ohms?
KA6 I CHECK VPWR CIRCUIT VOLTAGE
Key on, engine off. Yes ~ GO to IKA71.

RECONNECT EGR
Measure voltage between VPWR circuit at. the solenoid. RERUN Quick
EGR solenoid vehicle harness connector and Test.
battery ground.

ALL RIGHTS RESERVED
IEGR On/Off Control Pinpoint

Test
KA
KA7 I CHECK EGR CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes ~ GO to IKASI.

Quick Test.
breakout box and EGR circuit at the EGR
.
KASI CHECK EGR CIRCUIT FOR SHORT TO

GROUND
Key off, wait 10 seconds. Yes ~ GO to IKA91.

No
, ~ SERVICE short circuit.
RECONNECT all
Measure resistance between Test Pin 35 and Test - Quick Test.
KA9 I CHECK EGR CIRCUIT FOR SHORT TO POWER
Key off, wait 10 ~ecorids. Yes ~ REPLACE processor.

EGR solenoid disconnected. RECONNECT all
Breakout box installed, prQcessor disconnected. components. RERUN
Quick Test.
Measure resistance between Test Pin 35 and Test No ~ SERVICE short to
Pins 37 and 57 at the breakout box. power. REMOVE
breakout box.
Is each resistance greater thar:'l 10,000 ohms? RECONNECT all
components. RERUN
Quick Test. If code is
repeated, REPLACE
proc~ssor.

ALL RIGHTS RESERVED
DC Motor Idle Speed Control/Idle Pinpoint

Tracking Switch and Throttle Position KB
Sensor-l.9L CFI and 2.5L CFI Test
INote I
53, 58, 63, 68, 71, 73 or 93 is received during Quick Test or 6.0 or if you have been
directed here from Diagnosis By Symptom.
IRemember I
may be at fault: .
Throttle stop screw out of adjustment Vacuum leaks

8asic engine Throttle sticking
DC motor/Idle Tracking Switch assembly Throttle Position sensor (-98989-)

(-9N825-)
EEC-IV processor assembly (-12A650-)
Harness circuits ISC(+), ISC( -), ITS, TP,
VREF, and, SIG RTN

ITS
*TEST PIN 41 0~-ISC (-)-<~----."
~
ISC(+)
SIG RTN :
IS~ (-)
TEST PIN 46&BKIW-SIG RTN<
DC MOTOR IDLE
l
TEST PIN 280 ITS~~~ SPEED CONTROL
(TEST PIN 24 ON 2.5L CFI) VEHICLE HARNESS
CONNECTOR
TP
VREF
TEST PIN 210---ISC(+)-<~--- ........
THROTTLE SIG RTN
POSITION
SENSOR
(TP)
*TEST PIN 26~OIW-VREF-::: ...+-_---.
~
VREF
TP
VEHICLE
TEST PIN 47& DG/LG-TP--<~t----~ HARNESS SIG RTN
CONNECTOR
TEST PIN 46 0-BKIW-SIG RTN<~of----' THROTTLE POSITION
SENSOR VEHICLE
HARNESS CONNECTOR
*TEST PINS LOCATED ON THE BREAKOUT BOX.

ALL RIGHTS RESERVED

Tracking Switch and Throttle Position K8
Idle Tracking Switch Circuit

1.9L- CFI Pin 28 LG/W
2.5L CFI Pin 24 W/R
Test Pin 21 ISC(+)

110el CFI BR/W
2.5L CFI Y/BK
,
Test Pin 41 ISC( -)
110el CFI W/LB
2.5L CFI W

ALL RIGHTS RESERVED

KB 1 ISERVICE CODE 13:

CHECK DC MOTOR FOR PROPER OPERATION
Service Code 13 indicates that an idle speed control Yes ~ GO to IKB21.

rpm management error exists. The engine did not
return to a specified lower rpm prior to entering the No ~ REPLACE DC motor.
Dynamic Response Test portion of the Engine RERUN Quick Test.
Running Self-Test.
Possible causes:
- Faulty DC motor.
- open circuit in the idle speed control circuits.
- Short to ground in the idle speed control
circuits.
- Short to power in the idle speed control circuits.
- Faulty processor.
Disconnect DC motor vehicle harness connector.
I CAUTION!
Do not short to other pins when connecting
jumper wire.
Jumper ISC( +) circuit of DC motor to battery
positive and ISC( -) circuit of DC motor to battery
ground for 4 seconds.
ground and ISC( -) circuit of DC motor to battery
positive for 4 seconds.
Does the DC motor shaft extend to greater
than 2 inches (5 cm) and retract to less than
1.75 inches (4.4- cm) from mounting bracket
(see below)?
1.75 INCHES
4.4 em
~ J
......... =it _10::::-)
CW\=~t::=j1!jr-""--~?:CHES~
- 5cm -,
A9919C

ALL RIGHTS RESERVED

KB21 CHECK CONTINUITY OF ISC(+) AND

ISC( -) CIRCUITS
Key off, wait 10 seconds. Yes ~ GO to IKB31. -

Vehicle harness disconnected from DC motor.
Disconnect processor 60 pin connector. Inspect No ~ SERVICE open
for damaged or pushed out pins, corrosion, loose circuit(s). REMOVE
wires, etc. Service as necessary. breakout box.
RECONNECT all
Install breakout box, leave processor disconnected. components. RERUN
breakout box and ISC( -) circuit at the vehicle
harness connector and between Test Pin 21 at
the breakout box and ISC(+) circuit at the vehicle
harness connector.
KB31 CHECK ISC(+) AND ISC( -) CIRCUITS FOR

SHORTS TO GROUND
Key off, wait 10 seconds. Yes ~ GO to IKB41.

Breakout box installed, processor disconnected. No ~ SERVICE short
circuit(s). REMOVE
Pins 40, 46 and 60 at the breakout box. components. RERUN
Quick Test.
Is each resistance greater than 10,000 ohm"s?
KB41 CHECK ISC(+) AND ISC( -) CIRCUITS Fo.R

SHORTS TO POWER
Key on, engine off. Yes ~ REPLACE processor.

RECONNECT all
Pins 40 and 60 at the breakout box. No ~ SERVICE short
circuit(s). REMOVE "
Measure voltage between Test Pin 21 and Test breakout box.
Is each voltage less than 1 volt? components. RERUN
Quick Test.

ALL RIGHTS RESERVED

KB5 SERVICE CODE 58:

CHECK FOR FULL DC MOTOR RETRACTION
Service Code 58 indicates that the DC motor shaft Yes ~ GO to IKB71.

does not make contact with the throttle lever when
the idle speed control DC motor produces a signal No ~ GO to IKB61.
to extend the shaft.
Possible causes:
Open in the Idle Tracking Switch circuit
- Faulty DC motor
- Faulty processor
Disconnect vehicle harness from DC motor.
i CAUTION!
Jumper wire.
Jumper, at the DC motor connector, ISC( -) circuit
to battery positive and the ISC(+) circuit to battery
negative for 4 seconds.
Does the DC motor shaft retract away from
the throttle lever as shown?
MOVE THROTILE
AWAY FROM
DC MOTOR SHAFT
~
A9674-B
KB6 MEASURE DC MOTOR RETRACTION
Key off, wait 10 seconds. Yes ~ RECONNECT DC

motor. GO to Section 4
for throttle stop
DC motor fully retracted. adjustment procedure.
Measure the distance from the tip of the DC
motor shaft to the mounting bracket. Refer to No REPLACE DC motor.
figure in Step IKB1 I. , RERUN Quick Test.
Is the distance less than 1.75 inches (4.4 cm)?

ALL RIGHTS RESERVED

KB7 I CHECK IDLE TRACKING SWITCH STATE
Key off, wait 10 seconds. Yes ~ GO to IKBSI.

DC motor .fully retracted. No ~ REPLACE DC motor.
RERUN Quick Test.
DC motor shaft NOT touching the throttle lever.
Measure resistance between ITS circuit and SIG
RTN circuit at the DC motor connector.
KBsl CHECK CONTINUITY OF ITS AND SIG RTN

CIRCUITS

Vehicle harness disconnected from DC motor. REMOVE breakout box.
RECONNECT all
Disconnect processor 60 pin connector. Inspect components.
for damagea or pushed out pins, corrosion or RECONNECT DC
loose wires, etc. Service as necessary. motor. RERUN Quick
Install breakout box, leave processor disconnected. Test.
Measure resistance between Test Pin 46 at the No ~ SERVICE open
breakout box and SIG RTN circuit at the DC circuit(s). REMOVE
motor vehicle harness connector. breakout box.
Measure resistance between Test Pin 28 (Test Pin RECONNECT all
24 on 2.5l: CFI) at the breakout box and ITS components.
circuit at the DC motor vehicle harness connector. RECONNECT DC
motor. RERUN Quick
Is each resistance less than 5 ohms? Test.

CHECK IDLE TRACKING SWITCH STATE
Service Code 68 indicates that the DC motor shaft Yes ~ GO to IKB101.

is in contact with the throttle lever when the idle
speed control DC motor produces a signal to retract
the shaft.
No ~ REPLACE DC motor.
RERUN Quick Test.
Possible causes:
- Faulty DC motor
- Short to ground in the Idle Tracking Switch
circuit
- Faulty processor
Disconnect vehicle harness from DC motor.
Measure resistance between ITS circuit and .SIG
RTN circuit at the DC motor connector.
Is the resistance greater than 5 ohms?

ALL RIGHTS RESERVED

KB101 CHECK ITS CIRCUIT FOR SHORTS TO GND

Vehicle harness disconnected from DC motor. REMOVE breakout box.
RECONNECT all
Disconnect processor 60 pin connector. Inspect componen~s.
for damaged or pushed out pins, corrosion, loose RECONNECT DC
wires, etc. Service as necessary. motor. RERUN Quick
Install breakout box, leave processor disconnected. Test.
24 on 2.5L CFI) and Test Pins 40, 46 and 60 at No ~ SERVICE damaged
the breakout box. circuit(s). REMOVE
Is each resistance greater than 10,000 ohms? breakout box.
RECONNECT all
components.
RECONNECT DC
motor. RERUN Quick
Test.
KB 111 SERVICE CODE 93:

CHECK THROTTLE LEVER AND LINKAGE
Service Code 93 indicates that the DC motor is not Yes ~ REPLACE DC motor.
properly interacting with the throttle linkage. RERUN Quick Test.
Possible cause:
- Faulty DC motor No ~ SERVICE as necessary.
Key off, wait 10 seconds. RERUN Quick Test.
Inspect throttle for freedom of movement to wide-
open throttle and for damaged or bent throttle
lever.
Is throttle/throttle linkage functioning properly?
KB121 SERVICE CODE 23: CHECK THROTTLE PLATE

FOR CLOSING
Service Code 23 indicates that the throttle plate is Yes ~ RECONNECT DC

not in the proper position during Self-Test. motor.
Possible causes: GO to IKB131.
- Faulty Throttle Position sensor
- Open in Throttle Position sensor circuit No ~ SERVICE as necessary.
RERUN Quick Test.
- Faulty processor
Run Key On Engine Off Self-Test and disconnect
DC motor after it is fully retracted.
Remove air cleaner from throttle body.
Inspect throttle for freedom of movement and
proper closure. ,
Does throttle move freely and close without
obstruction?

ALL RIGHTS RESERVED

KB131 CHECK VOLTAGE OF VREF TO SIGNAL .

RETURN "
Key off, wait 10 seconds. Yes ~ RECONNECT TP

sensor.
Disconnect TP sensor at the throttle body. Inspect GO to IKB 141 .
Key on engine off.
~easure voltage between VREF circuit and SIG
connector.
Is the Yoltage between 4 and 6 YOIts?
KB141 CHECK THROTTLE STOP RPM
Run Key On Engine Off Self-Test and disconnect Yes. ~ REPLACE the TP
the DC motor after it has fully retracted and exit sensor. RECONNECT
Self Test. DC motor. RERUN
Quick Test.
Start engine and verify that the throttle stop rpm
is less than curb idle rpm. No ~ RECONNECT DC
Is the throttle stop rpm set below the curb motor. GO to the
idle rpm? adjustment procedure
in Section 4. ADJUST
throttle stop rpm.
RERUN Quick Test.
I
VERIFY THROTTLE OBSTRUCTION CODE
.
Service Code 73 indicates the processor did not Yes ~ REPLACE TP sensor.
detect a sufficient change in throttle position during RERUN Quick Test.
the Dynamic Response portion of the Engine
Running Self-Test. No ~ SERVICE other codes.
Possible causes:
- Faulty throttle position sensor or sensor circuit
- Faulty EGR system
- Faulty EGO sensor or sensor circuit
- Faulty idle tracking switch circuitry
Rerun Key On Engine Off Self-Test

ALL RIGHTS RESERVED


CHECK FOR CODES THAT COULD CAUSE
CODE 12
Service Code 12 indicates the system is not Yes ~ SERVICE these codes
capable of raising engine speed above curb idle. first. GO to Quick Test
Step 7.0 for direction.
Are Service Codes 31, 32, 34, 35, 41, or 58
present in Engine Running Self-Test?
No ~ GO to IKB241.
KB24 CHECK FOR STICKING THROTTLE LINKAGE
Check the throttle plates and/or linkage for Yes ~ GO to IKB251.

sticking or binding.
Check speed control linkage for proper No ~ SERVICE as necessary.
adjustment. RERUN Quick Test.
Does throttle open and close properly?
KB25 CHECK DC MOTOR FOR PROPER OPERATION

Disconnect vehicle harness from DC motor. RECONNECT DC
J CAUTION! motor. RERUN Quick
Test.
jumper wire. No REPLACE DC motor.
Jumper ISC( +) circuit of DC motor to battery RERUN Quick Test.
positi~e and ISC( -) circuit of DC. motor to battery
ground for 4 seconds.
ground and ISC( -) circuit of DC motor to battery
positive for 4 seconds.
Does the DC motor shaft extend to greater
than 2 inches (5 cm) and retract to less than
1.75 inches (4.4 cm) from mounting bracket
(see below)?
1.75 INCHESl
4.4 em
~~~-r._""'H""11J.~:-.--~[p>:: :1-)
~~--4~~~~~2INCHES
-- 5cm
A9919-C

ALL RIGHTS RESERVED


CHECK FOR ERRATIC IDLE
Service Code 19 indicates that the engine does not Yes ~ GO to IKB27 I.
remain at a specified lower rpm prior to entering the
Dynamic Response Test portion of the Engine No ~ GO to !KB2SI.
Running Self-Test. Possible causes:
- Faulty MAP/BP sensor or sensor circuit ,
- Faulty EGR sensor or sensor circuit

- Faulty EGO sensor or sensor circuit
- Faulty Idle Tracking Switch circuit
Engine should be at normal operating temperature.
AIC off.
Run engine for 3 minutes alternating between 30
second idles and 5 second part throttle modes.
Is the idle erratic at the end of the 3 minute
idle/part throttle test?
I
KB27 CHECK FOR ADDITIONAL SERVICE CODES IN
ENGINE RUNNING SELF-TEST .
I WARNING I Yes ~ GO to Quick Test Step

7.0 for direction.
EXTREME CAUTION MUST BE TAKEN WHEN

MAKING INSPECTIONS WITH ENGINE RUNNING.
No ~ GO to IKB2SI.
With engine at idle, check for vacuum leaks.
Are service codes 22, 31, 32, 34, 35, 41 or 58
present?
KB2S1 CHECK FOR PROPER OPERATION OF

THROTILE
Inspect the throttle plates andlor linkage for Yes ~ REPLACE DC motor.
proper function. RERUN Quick Test.
Does the throttle open and close properly?
RERUN Quick Test.

ALL RIGHTS RESERVED

KB29 ENGINE RUNNING SERVICE CODE 99: CHECK

PROCESSOR FUNCTION
Service Code 99 indicates the EEC system has not Yes ~ REPLACE processor.
learned to control the engine idle speed. RERUN Quick Test.
Possible cause:
No ~ SERVICE other codes
- Faulty processor as necessary.
With Self-Test deactivated, start the engine. DO
NOT touch the throttle.
Let the engine idle for 2 minutes.
Run Key On Engine Off Self-Test until the service
codes begin to be displayed, then deactivate Self-
Test.
KB30 ENGINE RUNNING SERVICE CODE 16 OR 17:

CHECK FOR RELATED MECHANICAL
PROBLEMS OR MISADJUSTMENTS
Service Code 16 could indicate that the accelerator Yes ~ SERVICE other EEC-IV
pedal was touched during the Engine Running Self- codes as necessary.
Test. If Service Code 17 was present, check for
electrical loads on the engine, (e.g. AIC or cooling No ~ SERVICE as necessary.
fan on during Self-Test). RERUN Quick Test.
Check for vacuum leaks.
Check for throttle plate andlor linkage sticking or
binding.
Check for speed control linkage for proper
adjustment.
Verify proper base engine timing.
Verify proper throttle stop screw adjustment
according to Section 4 of this manual.
Are all of the above areas okay?

ALL RIGHTS RESERVED

Sensor~ 1.9L CFI and 2.5L CFI Test
KB90 I CONTINUOUS MEMORY CODE 13:
A Continuous Memory Code 13 indicates that sometime in the last 40 warm-up cycles the TP
sensor rotation did not follow the reaction of the DC motor when idle speed control was in a
dashpot mode. This condition may be caused by:
The DC motor sticking at part throttle.
An open in the ITS circuit which, when coupled with other inputs to the processor, causes
the EEC-IV system to falsely enter "dashpot mode".
The TP sensor sticking at part throttle.
Each of these areas may generate Key On Engine Off (KOEO) or other Continuous Memory
Codes. Therefore, if service has been made for KOEO code 13 or 58, the Continuous Memory
Code, 13 can be considered serviced and erased from memory. If a Continuous Memory Code
38 is present along with the Continuous Memory Code 13, service the 38 first.
If these other codes were not present make the following checks:
Refer to IKB11 and check for FULL travel of the DC motor shaft. Replace the DC motor if
full travel is not possible. Leave the motor fully retracted.
With the DC motor fully retracted and the ITS not touching the throttle lever (I)S closed
circuit) check for an intermittent open in the ITS circuit. Turn the ignition key off and install
the breakout box. Make the necessary connector/pin inspections. With the DVOM on the
200 ohm scale, monitor between Test Pins 28 (Test Pin 24 on 2.5L CFI) and 46 while
tapping, wiggling, bending, etc. the DC motor connector and vehicle harness.
NOTE: Do not push in the idle tracking switch - While performing this wiggle test
The DVOM will change from less than 5 ohms to greater than 5 ohms if an open circuit is
created. Service as necessary. .
Check for a sticking TP sensor by monitoring TP voltage while moving the throttle from a
wide-open position to a closed throttle position. To do this it is necessary to install the
breakout box. Make the necessary connector/pin inspections. It is also necessary to fully
retract the shaft of the DC motor by placing a jumper between Test Pins 41 and 57. When
the motor has fully retracted, disconnect it at the vehicle harness and remove the jumper
wire from the breakout box. With the ignition key on and the DVOM on the 20 volt scale,
slowly move the throttle from wide-open to closed' throttle. The voltage should move from
more than 4 volts to less than 1.5 volts. If the TP sensor hangs up in midrange replace it;
otherwise no service should be made.

ALL RIGHTS RESERVED


A Continuous Memory Code 38 indicates that in the last 40 warm-up cycles the Idle Tracking
Switch was open (ITS touching the throttle) when the throttle angle was greater than the MAX
extension of the DC motor shaft. This could be caused by:
An open (either intermittent or hard fault) in the ITS circuit.
Idle Tracking Switch stuck open (pushed in position).
Either of these conditions may cause a code 58 to appear in Key On Engine Off (KOEO). If
service has been made for a KOEO code 58, the Continuous Memory Code 38 can be
considered serviced and erased from memory.
If KOEO code 58 was not present the following checks can be made:
With the DC motor fully retracted and the ITS not touching the throttle lever (ITS closed
circuit) check for an intermittent open in the ITS circuit. Turn the ignition key off and install
the breakout box. Make the necessary connector/pin inspections. With the DVOM on the
200 ohm scale, monitor between Test Pins 28 (Test Pin 24 on 2.5L CFI) and 46 while
tapping, wiggling, bending, etc. the DC motor connector and vehicle harness.
DO NOT PUSH IN THE IDLE TRACKING SWITCH.
The DVOM will change from less than 5 ohms to greater than 5 ohms if an open circuit is
created. Service as necessary. If an open circuit cannot be created, no service should be
made.

A Continuous Memory Code 71 indicates that sometime in the last 40 warm-up cycles the Idle
Tracking Switch was closed (ITS not touching the throttle lever) when the DC motor was in
"preposition" - [after the engine has been running and the ignition key is turned off the DC
motor fully retracts and then extends to a predetermined position for the next start-up]. This
can be caused by:
The ITS circuit shorted to GROUND or SIGNAL RETURN (intermittent or hard fault).
ITS stuck closed (ITS NOT in the pushed in position).
Either of these conditions may cause a Key On Engine Off (KOEO) code 68. If service has
been made for KOEO code 68, the Continuous Memory Code 71 can be considered serviced
and erased from memory.
If KOEO 68 was not present make the following checks:
Check the ITS circuit for an intermittent short to ground or Signal Return. Turn the ignition
key off. Enter the KOEO Continuous Monitor Mode per Quick Test Appendix. Systematically
tap, wiggle, or bend the vehicle harness while looking for an indication of a fault. If a fault
is created, service as necessary; otherwise no service should be made.
NOTE: Due to the nature of this Test Step, Code 71 will not reappear in memory if a
fault Is found.

ALL RIGHTS RESERVED
EEC-'V Pinpoint Test Procedures 17263

Sensor - 1.9L CFI and 2.5L CFI Test
.
KB931 CONTINUOUS MEMORY CODE 53:

EXERCISE TP SENSOR
Continuous Memory Service Code 53 indicates the Yes ~ GO to IKB941.

Throttle Position sensor output signal was higher
than the Self-Test maximum of 4.7 volts. Failure No .~ GO to IKB9SI.
mode indicates WOT to processor.
Possible causes:
- Faulty Throttle Position sensor
- Faulty processor
- Short to power in throttle position sensor circuit
Enter Key On Engine Off Self-Test.
Use Continuous Monitor Mode. Refer to Quick
Test Appendix.
- Move throttle slowly to WOT position.
lightly tap on TP sensor (simulate road
shock).
- Wiggle TP vehicle harness connector.
- Is a fault indicated?
POWER OR VREF
CIRCUIT
[F
/VREF~@
>-TP SIG <) u.t' )8
~. RTN-._--J/
PROCESSOR HARNESS TP SENS'OR
A9468-A

ALL RIGHTS RESERVED
17-26.4 EEC-IV Pinpoint Test Procedures
DC ~otor Idle Speed Control/Idle Pinpoint

KB941 MEASURE THROTTLE POSITION SIGNAL

VOLTAGE WHILE EXERCISING TP SENSOR

INSPECT connectors. If
Disconnect processor 60 pin connector. Inspect connector and
for damaged or pushed out pins, corrosion, loose terminals are good,
wires, etc. Service as necessary. REPLACE TP sensor.
CLEAR Continuous
Install breakout box and connect processor to Memory (REFER to
breakout box. Quick Test Appendix).
Connect a DVOM from Test Pin 47 to Test Pin REFER to Fuel/Engine
46 at the breakout box. Shop Manual Group
and RERUN Quick
DVOM on 20 volt scale. Test.
.Key on, engine off.
No ~ Throttle position sensor
While observing DVOM, perform the following: overtravel may have
caused the Continuous
- Move throttle slowly to closed position and
Memory Code 53.
lightly tap on TP sensor (simulating road
Sensor service is not
shock). required. To verify
- Wiggle TP vehicle harness and connector. vehicle harness
integrity,
Does the fault occur below 4.25 volts? GO to IKB951.
I
KB95 CHECK EEC-IV HARNESS
Enter Key On Engine Off Continuous Monitor Yes ~ ISOLATE fault and
mode. make necessary
repairs. CLEAR
Observe VOM or STAR LED for a fault indication
while performing the following: . Continuous Memory
Appendix). RERUN
Referring to the illustration in Step IDH90 I, grasp
Quick Test
connector. Wiggle, shake or bend a small section
of the EEC-IV system vehicle harness while No .~ GO to IKB961.
working your way to the dash panel. Also wiggle,
shake or bend the EEC-IV vehicle harness from
the dash panel to the processor.

ALL RIGHTS RESERVED

" TEST STEP RESULT ~ ACTION TO TAKE
KB961 CHECK PROCESSOR AND HARNESS

CONNECTORS

Disconnect processor 60 pin connector.
Inspect both connectors and connector terminals diagnosis using the .
for obvious damage or faults. EEC-IV Monitor box,
Are connectors and terminals OK? REFER to Section 18
EEC-IV Monitor Box:
\
"Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory.
REFER to Quick Test
Appendix (RERUN
Quick Test).
CLEAR Continuous
Memory. REFER to
Quick Test Appendix.
REPEAT Quick Test.
KB971 CONTINUOUS MEMORY CODES 23 or 63:

EXERCISE TP SENSOR
Continuous Memory Service Codes 23 or 63 indicate Yes ~ DISCONNECT and

the Throttle Position sensor output signal is less INSPECT connectors. If
than the Self-Test minimum of 0.2 volts. Failure connector and
mode indicates closed throttle to the processor. terminals are good,
Possible causes: REPLACE TP sensor.
CLEAR Continuous
- Faulty Throttle Position sensor Memory. REFER to
- Open in Throttle Position sensor vehicle harness Fuel/Engine Shop
circuits Manual Group and
RERUN Quick Test.
- Short to ground in Throttle Position sensor
vehicle harness circuits
- Faulty processor No ~ GO to IKB9S1 .
Using Key On Engine Off Continuous Monitor
mode, observe YOM or STAR LED for indication ..
of a fault while performing the following:
Move throttle slowly to WOT position.
Release throttle slowly to closed condition.
Lightly tap on TP sensor (simulate road shock).
Wiggle TP vehicle harness connector.

ALL RIGHTS RESERVED

Sensor - 1.9L CFI and 2.5L CFI Test
KB9s1 CHECK EEC-IV VEHICLE HARNESS
Enter Key On Engine Off Continuous Monitor Yes ~ ISOLATE fault and
mode. make necessary
repairs. CLEAR
Observe VOM or STAR LED for a fault indication Continuous Memory
while performing the following: (REFER to Quick Test
Appendix). RERUN
Referring to the illustration in Step IDH94 I, grasp Quick Test.
connector. Wiggle, shake or bend a small section
of the EEC-IV system vehicle harness while No ~ GO to IKB991.
working your way to the dash panel. Also wiggle,
shake or bend the EEC-IV vehicle harness from
the dash panel to the processor.
KB991 CHECK PROCESSOR AND VEHICLE HARNESS

CONNECTORS

Inspect both connectors -and connector terminals diagnosis using the
for obvious damage or faults. EEC-IV Monitor box,
REFER to. Section 18
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.
CLEAR Continuous
Memory (REFER to
RERUN Quick Test.

ALL RIGHTS RESERVED
Air Management System Pinpoint.

KC
(AMljAM2) Test
INote I
You should enter this Pinpoint Test only when a Service Code 44, 45, 46, 81, 82 or 94
is received during Quick Test. .
IRemember I
may be at fault:
Thermactor System
Belt
Pump
Valve
AM1 and AM2 Solenoid Valve Assemblies (-9H465-)
Harness circuits: AM 1/AM2 and VPWR
Vacuum Supply

ALL RIGHTS RESERVED
Air Management System Pinpoint

KC
(AMl/AM2) Test

*TEST PIN 51 @) AM 1--+:::::I1I:::::::I::t++-=:I AM1-.ffil.
::t--
(TEST PIN 38 5.0l MA SEFI
AND All LINCOLN TOWN CARS) VPWR~
R
TEST PIN 37
AM1/AM2
VPWR
SOLENOID CONNECTORS
TEST PIN 57. R
VPWR--f6:\. .
TEST PIN 11 (!) AM2-----tII"..,....+t+...~ AM2~
(TEST PIN 32 5.0l MA SEFI AND
All LINCOLN roWN CARS)
AM 1 AND AM 2 SOLENOID
VEHICLE HARNESS CONNECTORS

Test Pin 11 Test Pin 38

or 32 AM2 or 51 AM1
Car:
5.0l SEFI
5.0l SEFI MA
except
lG/BK
Lincoln Town
Car
5.0l SEFI MA
lincoln Town D y
Car
2.3l HSC W/R
Truck:
4.9l, 5.0l. 5.8L.
7.5L W/BK W/R
E-Series
4.9L. 5.0L, 5.8L,
7.5L BA '. WID
F-Seriesl Bronco

ALL RIGHTS RESERVED

KC
(AMljAM2) Test
TEST STEP
.
RESULT ~ ACTION TO TAKE
KC1 ISERVICE CODES 44 (94), 45 AND 46:

VERIFY VACUUM LINE ROUTING ..
Service Code 44 (94) indicates that Thermactor' Air Yes ~ S~RVICE routing or
system is inoperative. - faults. RERUN Quick
Test.
Service Code 45 indicates that Thermactor air is
flowing upstream when not requested.
No ~ For Service Code 44
Service Code 46. indicates that Thermactor is not (94):
being bypassed when requested. GO to IKC41.
Possible causes:
For Service Code 45:
- Vacuum hoses leaking, blocked, or kinked. - . GO to IKC21.
- Diverter valve,. thermactor pump inoperative. For Service Code 46:
- Air Management Solenoid(s) defective, blocked. GO to IKC31.
Verify proper vacuum line routing to the AM1 / AM2
solenoids and to the bypass diverter valve. Refer ..
to VECI decal. 1
Check for kinked or blocked vacuum lines.

Check for kinked or blocked air hoses.
Check for disconnected or cracked vacuum lines.
Were any problems found?
KC21 ATTEMPT TO ELIMINATE SERVICE .

CODE 45 (AM2 ONLY) ,
Disconnect vacuum line on diverter valve and cap Yes ~ EEC-IV system OK.
vacuum -line. REFER to Section 10
for Thermactor System
Key off, wait 10 seconds. diagnosis.
Repeat Engine Running Self-Test and record
service codes. No ~ GO to IKc41.
Is Code 45 present?
KC31 ATTEMPT TO ELIMINATE SERVICE

CODE 46 (AM1 ONLY)
Disconnect vacuum line on bypass valve and cap Yes ~ EEC-IV system OK.
vacuum line. REFER to Section 10
for Thermactor System
Key off, wait 10 seconds. diagnosis.
Repeat Engine Running Self-Test and record
codes. No ~ GO to IKC41.
Is Code 46 present?

ALL RIGHTS RESERVED
.Air Management System Pinpoint

KC
(AMljAM2) Test
KC41 ENTER OUTPUT STATE CHECK

(REFER TO QUICK TEST APPENDIX)
NOTE: Do not use STAR tester for this Step, Yes ~ REMAIN in Output
use a VOM/DVOM. State Check. GO to
IKCsl.
Disconnect electrical connector on. the speed No ~ DEPRESS throttle to
control servo; if equipped. WOT and RELEASE. If
STO voltage does not
DVOM on 20 volt scale. go high, GO to
Connect DVOM negative test lead to STO circuit rinp,int Test Step
at the Self-Test connector and positive test lead QC1 .
to battery positive.
Leave equipment
Jumper STI circuit to SIG RTN at the Self-Test hooked up.
connector.
Perform Key On "Engine Off Self-Test until the
completion of the Continuous Memory Test Codes.
DVOM will indicate less than one volt when test
is complete.
Does DVOM" indicate a change to a high signal
voltage?
KCsl CHECK AM1/AM2 SOLENOID ELECTRICAL

OPERATION
DVOM on 20 volt scale. Yes ~ REMAIN in Output

State Check. GO to
Disconnect AM 1 and AM2 solenoids. IKC61.
Connect DVOM positive test lead to VPWR circuit
and negative test lead to AM 1 circuit on AM 1 No ~ REMOVE jumper. GO
solenoid vehicle harness connector. to IKegl.
While observing DVOM depress and release the
throttle several times (to cycle output On and
Off).
Repeat for AM2 solenoid. Connect positive test
lead to VPWR circuit and negative test lead to
AM2 circuit on .AM2 solenoid vehicle harness
connector.
Does each solenoid circuit cycle On and Off?

ALL RIGHTS RESERVED

KC
(AMl/AM2) Test
KC61 CHECK AM1/AM2 SOLENOID FOR VACUUM .-

CYCLING
Install vacuum pump to the AM1 solenoid vacuum Yes ~ GO .to IKC71.
supply port and install a vacuum gauge to the
AM 1 output port.
No ~ REPLACE solenoid
While cycling outputs On and Off (by depressing assembly. RERUN
and releasing throttle), observe the vacuum gauge Quick Test.
at the output.
NOTE: Maintain vacuum at source.
Repeat for AM2 solenoid. Connect vacuum pump
to the AM2 solenoid vacuum supply port and
connect a vacuum gauge to the AM2 output port.
Cycle output On and Off.
Does each solenoid cycle vacuum output On
and Off?
KC71 CHECK AM1/AM2 SOLENOIDS FOR INTERNAL

VACUUM LEAKS
Vacuum pump connected to the AM 1 solenoid Yes ~ SERVICE vacuum

supply port. source blockage or
Vacuum gauge connected to the AM1 solenoid leakage. RERUN Quick
output port. Test.
Apply 15 in-Hg vacuum and observe gauge.
Repeat steps above for AM2 solenoid. No ~ REPLACE solenoid
assembly. RER~N
Does vacuum gauge reading hold for each Quick Test.
solenoid?
Keel SERVICE CODE 81 AND 82: .

CHECK VOLTAGE OF VPWR CIRCUIT
Service Code 81, 82 indicates that voltage output

for Thermactor Air solenoid(s) did not change when
activated.
Yes . GO to \KC9\.
No ~ SERVICE harness
Possible causes: circuit open.
- AM1 / AM2 circuits shorted to power. RECONNECT
AM 1/ AM2 solenoids.
- AM 1/ AM2 circuits open or grounded. RERUN Quick Test.
- AM 1/ AM2 solenoid resistance out of range.
- Faulty processor.
Key on, engine off.
Measure voltage between AM1 solenoid VPWR
circuit and battery ground.
Repeat for AM2 solenoid.

ALL RIGHTS RESERVED
17272 EECIV Pinpoint Test Procedure~

KC
(AMljAM2) Test
KC9 I MEASURE AM1/AM2 SOLENOID RESISTANCE
Key off, wait 10 seconds. Yes ~ GO to IKC1ol.

No ~ REPLACE AM1/AM2
Disconnect AM1 solenoid connector and measure solenoid assembly.
solenoid resistance. RERUN Quick Test.
Disconnect AM2 solenoid connector and measure
solenoid resistance.
Is each resistance between 50 and 100 ohms?
I
KC10 CHECK CONTINUITY OF AM1 AND AM2
CIRCUITS .
Key off, wait 10 seconds. Yes ~ GO to IKc111.

for damaged or pushed out pins, corrosion, loose No ~ SERVICE harness open
wires, etc. Service as necessary. circuit. REMOVE
breakout box.
Install breakout box, leave processor disconnected. RECONNECT processor
and AM1/AM2
DVOM on 200 ohm scale. solenoids. RERUN
Measure resistance between Test Pin 51 (Test Pin Quick Test.
38 for 5.0L MA SEFI and all Lincoln Town Cars)
at breakout box and AM 1 circuit at vehicle
harness connector.
32 for 5.0L MA SEFI and all Lincoln Town Cars)
at the breakout box and AM2 circuit at vehicle
harness connector.

ALL RIGHTS RESERVED

KC'
(AMljAM2) Test
KC111 CHECK FOR SHORT TO GROUND
Key off, wait 10 seconds. Yes ~ GO to IKC12\:

DVOM on 200,000 ohm.
Breakout box installed, processor disconnected. ground. REMOVE
breakout box.
Disconnect AM 1/AM2 solenoids. RECONNECT processor
Measure resistance between 'Test Pin 51 (Test Pin and AM1/AM2
38 for 5.0L MA SEFI and all Lincoln Town Cars) solenoids. RERUN
and Test Pins 40, 46 and 60 and between Test Quick Test.
Pin 11 (Test Pin 32 for 5.0L MA SEFI and all
Lincoln Town Cars) and Test Pins 40, 46 and 60
KC121 CHECK FOR SHORT TO POWER

DVOM on 200,000 ohm scale. RECONNECT AM1/
Breakout box installed, processor disconnected. AM2 solenoid. RERUN
Quick Test.
AM 1/AM2 solenoids disconnected.
-
Measure resistance between Test Pin 51 (Test Pin No ~ SERVICE short to
38 for 5.0L MA SEFI and all Lincoln Town Cars) power. REMOVE
and Test Pins 37 and 57, and between Test Pin breakout box.
11 (Test Pin 32 for 5.0L MA SEFI and all Lincoln RECONNECT processor
and AM1/AM2
Town Cars) and Test Pins 37- and 57 at the
solenoids. RERUN
breakout box. Quick Test. If code is
Is each resistance greater than 10,000 ohms? present, REPLACE
processor.

ALL RIGHTS RESERVED
Pinpoint
ICanister Purge (CANP) Test
KD
INote I
You should enter this Pinpoint Test only when a Service Code 85 Is received during
IRemember I
CANP solenoid (-9C915-)
Harness circuits: CANP and VPWR

~
"TEST PIN 31 (!)
(TEST PIN 32 ALL 1.9L EFI ENGINES)
CANP----------4I~/Jl
_---~(~I{~clofl~!J
m
iVl
(TEST PIN 35 ALL 1.9L CFI ENGINES) \":="
CANISTER PURGE (CANP)
SOlENOID VEHICLE
HARNESS CONNEcroR
TEST PIN 37 @ - - - - - V P W R - - - - - -...
TEST PIN 57 0 VPWR--------'

All HARNESS CONNECTORS VIEWED INTO MATING SURFACE.
A9671E
Test Pin 31, 32

Test Pin 37/57
or 35
YPWR
CANP
Application Wire Color Wire Color
2.9L Car BR/W BK
3.0L Probe W/BK BK/W
All Others GY/Y R

ALL RIGHTS RESERVED
Il...oo-c_a_D_i_st_e_r_p_u_r_g_,e_<C_AN_"..p_)
... ---:--_---11 ~P_i;_:_:_:_D_t--' ....._K_D_.. . .
KDt IENTER OUTPUT STATE CHECK

NOTE: Do not use STAR tester for this step, use .Yes" ~ REMAIN in Output
VOM/DVOM. State Check. GO to
Key off, wait 10 seconds. IKD21.
control servo; if equipped. No ~ DEPRESS throttle to
DVOM on 20 volt scale. WOT and release. If
STO voltage does not
Connect DVOM negative test lead to STO circuit go high, leave
at Self-Test connector and positive test lead to equipment hooked up
battery positive. and GO to Pinpoint
Jumper STI circuit to SIG RTN at the Self-Test Test Step IQC11
"connector.
Perform Key On Engine Off Self-Test until the"
DVOM will indicate less than 1.0 volt when test is
comp'leted.
Does voltage increase?
KD21 CHECK CANISTER PURGE (CANP)

SOLENOID ELECTRICAL OPERATION
Key on, engine off. Yes ~ GO to IKD3\.

Disconnect CANP solenoid.
.~
Connect DVOM positive test lead to VPWR circuit No R~MOIE jUTper.
and negative test lead to CANP circuit at the GO to KD6 .
CANP solenoid vehicle harness connector.
DVOM on 20" volt scale.
While observing DVOM depress and release the
throttle several times to cycle output.
Does CANP circuit cycle?
KD31 CHECK CANP SOLENOID FOR VACUUM

LEAKS
Key on, engine off. Yes ~ REMAIN in Output

CANP solenoid disconnected. State Check. Leave
vacuum pump setup in
Disconnect vacuum hose at CANP solenoid on
place. GO to IKD41 .
manifold vacuum side of CANP solenoid.
Apply 16 in-Hg (53 kPa) of vacuum to manifold
vacuum side of CANP solenoid. No ~ REPLACE CANP
Does CANP solenoid hold vacuum for 20 Test. If symptom is still
seconds? present, GO to Section
7, Evaporative Emission
System diagnosis.

ALL RIGHTS RESERVED
17-276 EEC-IV Pinpoint Test Procedures'
Pinpoint
KD
KD41 CHECK CANP SOLENOID FOR MECHANICAL

OPERATION
While remaining in output state check, reconnect Yes ~ CHECK hose from
CANP solenoid. CANP solenoid to
canister for cracks,
Apply 16 in-Hg (53 kPa) of vacuum to manifold leaks, etc. If OK,
vacuum side of CANP solenoid. REMOVE Jumper from
STI to SIGNAL
Depress and release throttle. RETURN.
Is vacuum released? GO to IKOsl.
No ~ CHECK hose from

CANP solenoid to
canister for blockage or
kinks. If OK, REPLACE
CANP solenoid.
RERUN Quick Test.
KD5 I CHECK FOR VACUUM TO CANP SOLENOID
Disconnect vacuum hose at CANP solenoid at Yes ~ EEC-IV system OK. If

manifold vacuum side. a symptom is still
present, GO to Section
Start engine. 7, Evaporative Emission
Systems Diagnosis.
Is vacuum present at engine vacuum hose?
No ~ CHECK vacuum line for

proper routing, kinks,
leak or blockage. If
OK, REFER to Engine
probable subjects
affecting engine
vacuum.

ALL RIGHTS RESERVED
l_c_a_D_is_t_e_r_p_u_r_g_e_(_C_AN_P_> --JI- ~P_i;_:_:t_iD_t~ "",-_K_D_-.I
KD6 I MEASURE CANP SOLENOID RESISTANCE
Service Code 85 indicates a failure in the Canister Yes ~ GO to IK071.

Purge solenoid (CANP) circuit.
Possible causes are: No ~ REPLACE CANP
- Faulty CANP solenoid Test.
- Open harness
- Shorted (Power or Ground) harness
- Faulty processor.
Disconnect CANP solenoid.
Measure CANP solenoid resistance.
Is resistal)ce between 40 and 90 ohms?
KD7 I CHECK VOLTAGE OF VPWR CIRCUIT
Key on, engine off.' Yes ~ GO to IKosl.

CANP solenoid disconnected.
No ~ SERVICE open harness
circuit. RECONNECT
Measure' voltage between VPWR at the CANP CANP solenoid.
solenoid vehicle harness connector and battery RERUN Quick Test.
ground.
KD8 I CHECK CONTINUITY OF CANP CIRCUIT

Key off, wait 10 seconds. Yes ~ GO to IK091.
Disconnect processor 60 pin connectors. Inspect
Install breakout box, leave processor disconnected. Quick Test.

35 for 1.9L CFI engines, Test Pin 32 for 1.9L EFI
engines) at the breakout box and CANP circuit at
the CANP solenoid vehicle harness connector.

ALL RIGHTS RESERVED
Pinpoint
KD
KD91 CHECK CANP CIRCUIT FOR SHORT TO

GROUND
Key off, wait 10 seconds. Yes ~ GO to IKD101.

breakout box.
Measure resistance between Test Pin 31 (Test Pin components. RERUN
35 for 1.9L CFI engines, Test Pin '32 for 1.9L EFI Quick Test.
engines) and Test Pins 40, 46 and 60 at the
breakout box.
I
KD10 CHECK CANP CIRCUIT FOR SHORT TO
POWER
.
RECONNECT CANP
CANP solenoid disconnected. solenoid. REMOVE
Breakout box installed, processor disconnected. breakout box. RERUN
Quick Test.
Measure resistance between Test Pin 31 (Test Pin No ~ SERVICE short to
35 for 1.9L CFI engines, Test Pin 32 for 1.9L EFI power. REMOVE
engines) and Test Pins 37 and 57 at the breakout breakout box.
box. RECONNECT all
components. REPEAT
Is each resistance greater than 10,000 ohms? Quick Test. If code is
repeated, REPLACE
processor. RERUN
Quick Test.
.-

ALL RIGHTS RESERVED
Pinpoint
KD
KD151 CHECK IF 9ANP WAS CAUSE OF SERVICE

CODE 16 OR 26
Key off. Yes ~ GO to IKD11.

Disconnect vacuum hose at CANP solenoid on
canister side. No ~ For CODE 26:
CHECK for causes of
Start engine and let idle. an incorrect engine
speed or a vacuum
Is vacuum present on canister side of canister leak.
purge solenoid?
For CODE 16:
CHECK for vacuum
. leaks at injector
O-rings, vacuum lines/
fittings, excessive PCV,
or inlet pin leak
between air meter and
throttle body. SERVICE
as necessary. RERUN
Quick Test.

ALL RIGHTS RESERVED
Idle Speed Control Pinpoint

KE
(Bypass Air) Test
INote I
48 is received during Quick Test or when directed here from Pinpoint Test 00 .
IRemember I
may be at fault:
Engine not up to operating temperature
Engine over operating temperature
A/C input (electrical problem)
Throttle Speed Control Linkage
Throttle Sticking or Linkage Binding.
Rpm in Self-Test only
ISC Solenoid (-9F715-)
Harness circuits: ISC and VPWR

ALL RIGHTS RESERVED

KE
(Bypass Air) Test
IPinp~int Test Schematic I

1II!!!!!!!!!!Il
*TEST PIN 21 C!>~----ISC--------------~~~nl~

ell
1
TEST PIN 37 C!>......- - - - v p w R - - - - - - - _ - - -.......
IDLE SPEED CONTROL
(BYPASS AIR) SOLENOID
TEST PIN 57 @)~----VPWR - - - - - - -... VEHICLE HARNESS
. CONNECTOR

Test Pin 21 ISC

1.9L EFI
Taurus/Sable O/BK
Aerostar
1.9L MA SEFI ' BL/O
Tempo/Topaz BR/W
Mustang
Crown Victoria/
Grand Marquis . W/LB
Mark VII
F-Series, Bronco
Thunderbird/Cougar R/LG
Probe W/R
Ranger/Supercab
Bronco \I GY/W
E-Series
Scorpio BR/Y
Test Pin 37 and 57 VPWR

1.9L MA SEFI W/R
Scorpio BK
Probe R/BK
All Others R
,/

ALL RIGHTS RESERVED

KE
(Bypass Air) Test
-
KE 1 ISERVICE CODE 12:

CHECK FOR RPM DROP
1.9L EFI: Yes ~ GO to IKE21.

Service Code 12 indicates that during Engine
Running Self-Test, engine was unable to achieve No ~ GO to IKE31.
the Self-Test upper limit.
All Others:
Running Self-Test, engine rpm could not be
controlled within the Self-Test upper limit band.
- Open or shorted circuit
- Throttle linkage binding
- Improper idle set
- Throttle body/ISC solenoid contamination
- Items external to Idle Speed Control system
that could affect engine rpm.
- Faulty ISC solenoid
- Faulty processor
Key off.
Connect engine tachometer.
Start engine.
Disconnect ISC harness connector.
Does rpm drop or stall?
KE2 I CHECK FOR EGR CODES
Are Service Codes 31, 32, 33 or 34 present? Yes ~ RECONNECT ISC

solenoid. GO to Quick
Test Step 7.0 for
appropriate Pinpoint
Test.
No ~ GO to \KE31.

ALL RIGHTS RESERVED

KE
(Bypass Air) Test
KE3 I CHECK FOR OTHER EEC CODES I
Are Service Codes 22, 41, 42, 91 or 92 Yes ~ RECONNECT ISC

present? solenoid.
For 1.9L EFlwith

Code 42 present:
., . GO to IKE4/ .
For all others:

GO' to Quick Test Step
, 7.0 for appropriate
Pinpoint Test.
No ~ GO to IKE41.
KE4 I MEASURE ISC SOLENOID RESISTANCE
Key off. Yes ~ GO to IKESI.

ISC solenoid disconnected.
DVOM on 200 ohm scale. No ~ REPLACE ISC solenoid.
RERUN Quick Test.
Measure solenoid resistance.
NOTE: Due to diode in solenoid, place DVOM
(+) lead on VPWR pin and (-) lead on ISC
pin
1
*~:I'-+t------ISC
I VPWR
u
ISC SOLENOID
CONNECTOR A9225-A
KESI CHECK FOR INTERNAL SHORT TO ISC

SOLENOID CASE
Key off. Yes ~ GO to IKE61.

DVOM on 200,000 ohm scale. No ~ REPLACE ISC solenoid.
RERUN Quick Test.
Measure resistance from either ISC solenoid pin
to ISC housing.

ALL RIGHTS RESERVED
Idle Spe~d Control Pinpoint

KE
(Bypass Air) Test
KE6 I CHECK VPWR CIRCUIT VOLTAGE
Key on, engine off. Yes ~ GO to IKE71.

DVOM on 20 volt scale. No ~ SERVICE open circuit.
RERUN Quick Test.
Measure voltage between VPWR circuit at the ISC
solenoid vehicle harness connector and battery
ground.
Is Yoltage greater than 10.5 YO Its?
KE7 I CHECK ISC CIRCUIT CONTINUITY
Key off. Yes ~ GO to IKESI.

Disconnect processor and inspect both 60 pin No ~ SERVICE open circuit.
connectors for damaged or pushed out pins, REMOVE breakout box.
corrosion, loose wires, etc. Service as necessary. RECONNECT all
components. RERUN
Quick Test.
breakout box and ISC circuit at ISC solenoid
KEsl GROUND'
CHECK ISC CIRCUIT FOR SHORT TO
Key off. Yes ~ GO to IKE9\.

ISC solenoid disconnected. No ~ SERVICE short circuit.
DVOM on 200,000 ohm sCale.
RECONNECT all
Pins 40, 46 and 60 at the breakout box. Quick Test.
KEg I CHECK ISC CIRCUIT FOR SHORT TO POWER
Key off. Yes' .~ GO to IKE101.

Breakout box installed, .processor disconnected.
ISC solenoid disconnected. No ~ SERVICE short circuit.
RECONNECT all
Pin 21 at the breakout box. Quick Test. If code or
Is resistance greater than 10,000 ohms? . symptom is still
present, REPLACE
processor.

ALL RIGHTS RESERVED

KE
(Bypass Air) Test
I
KE10 CHECK FOR ISC SIGNAL FROM THE
PROCESSOR
'. ~ey off. Yes ~ GO to IKE 11 I.

Reconnect processor to breakout box. REMOVE breakout box.
RERUN Quick Test.
Reconnect ISC solenoid.
Connect DVOM 'between Test Pin 21 and Test
Pin 40.
. .
Start engine.'
Slowly increase and decrease rpm.
Does DVOM voltage vary?
KE111 CHECK BASE IDLE
Is idle speed within specification? - Yes ~. For 3.8L SEFI's:

(Refer to Section 4) REPLACE ISC solenoid.
RERUN Quick Test.
For all others:

REMOVE ISC solenoid
and INSPECT for
contamination. CLEAN
as necessary. RERUN
Quick Test. If code I
symptom is present,
REPLACE ISC solenoid.
No ~ RESET idle to
specification. REFER to
Section 4 for idle set
procedure. RERUN
Quick Test. If UNABLE
to RESET idle to
tPeCifiFation, GO to
KE12 .
. .

ALL RIGHTS RESERVED

KE
(Bypass Air) Test
TEST STEP
KE12 CHECK FOR PROBLEMS AFFECTING PROPER

ENGINE SPEED
Check throttle linkage and/or speed control Yes ~ For 3.8L SEFI's:
linkage for binding. REPLACE ISC solenoid.'
RERUN Quick Test.
Inspect throttle body for contamination.
Check engine vacuum hoses. Refer to VECI For all others:
decal. REMOVE ISC solenoid
Check for leaks around ISC solenoid (ex. and INSPECT for
mounting gasket, etc.). contamination. CLEAN
as necessary. RERUN
Are all the above checks OK? Quick Test. If code/
symptom is present,
RECONNECT
processor. RERUN
Quick Test.
KE15 SERVICE CODE 13:

VERIFY IDLE SPEED IS WITHIN
SPECIFICATION
1.9L EFI:
Running Self-Test, engine rpm did not obtain the
Yes . For 3.8L SEFI's:
RERUN Quick Test.
Self-Test lower limit.
For all others:
All others: REMOVE ISC solenoid
Service Code 13 indicates that during Engine and INSPECT for
Running Self-Test, Engine rpm could not be contamination. CLEAN
controlled within the Self-Test lower limit band. as necessary. RERUN
Quick Test. If code/
Possible causes are: symptom is present,
-
.
Improper idle set. REPLACE ISC solenoid.
- Vacuum leaks.
No RESET idle to
- Throttle linkage binding.
- Throttle plates open. Section 4 for idle set
- Improper ignition timing (TFI vehicles only). procedure. RERUN
Quick Test. If UNABLE
- Throttle body/ISC solenoid contamination. to RESET idle to
- ISC circuit short to ground. tpeCifi,ation, GO to
KE16 .
- Faulty ISC solenoid.
Is idle speed within specification?
(Refer to Section 4)

ALL RIGHTS RESERVED

KE
(Bypass Air) Test
KE161 CHECK FOR CONDITIONS AFFECTING IDLE ~ .
Check engine vacuum hoses for leaks. Refer to Yes ~ GO to IKE171.

VECI decal.
No .~ SERVICE as, necessary.
Check throttle linkage and/or speed control
linkage for binding. , RERUN Quick Test.
Check that throttle plates are fully closed.

Check for induction system leaks. (ex. ISC
solenoid to throttle body gasket.) ,
Check throttle body for contamination.

Verify base timing is to specification (TFI vehicles
only). Refer to VECI decal.
Are all the above checks OK?
KE171 CHECK FOR INTERNAL SHORT TO ISC I
SOLENOID CASE
Key off. . Yes ~ GO to IKE1SI.

Disconnect ISC solenoid.
No ~ REPLACE ISC solenoid.
DVOM on 200,000 ohm scale. RERUN Quick Test.
Measure' resistance from either ISC solenoid pin
to ISC housing.
KE181 CHECK ISC CIRCUIT FOR SHORT TO

GROUND "
Key off. Yes ~ GO to IKE191 .

Disconnect th~ processor 60 pin connector. REMOVE breakout box.
Inspect for damaged or pushed out pins, RECONNECT all
corrosion, loose wires, etc. Service as nec~ssary. components. RERUN
Quick Test.
'.
Measure resistance between Test Pin 21 and Test :
Are all resistances greater than 10,000 ohms?

ALL RIGHTS RESERVED

KE
(Bypass Air) . Test
KE191 CHECK PROCESSOR OUTPUT
Key off. Yes ~ For 3.8L SEFI's:

RERUN Quick Test.
Reconnect ISC solenoid. For all others:
REMOVE ISC solenoid
and INSPECT for
Connect DVOM between Test Pin 21 and Test contamination. CLEAN
Pin 40. as necessary. RERUN
Start engine. Quick Test. If code/
symptom is present,
Slowly increase. and decrease rpm.
REPLACE ISC solenoid
Does DVOM voltage vary?
RERUN Quick Test.

CHECK FOR LOW FLOW UNMETERED AIR
Service Code 47 indicates that the measured airflow Yes ~ SERVICE as necessary.
at base idle was lower than expected. RERUN Quick Test.
- Air/vacuum leaks in fuel charging assembly. No ~ EEC system OK for
metered air. GO to
- Purge solenoid/injector O-rings. Quick Test to service
Check for holes, cracks, and/or disconnections in other codes if
fuel charging assembly (manifold gaskets, vacuum necessary.
lines, vacuum tree, etc).
Check for stuck-open purge solenoid and/or
injector O-rings.
Are any faults present?
KE21 I
SERVICE CODE 48:
CHECK FOR HIGH FLOW UNMETERED AIR
Service Code 48 indicates that the measured airflow Yes ~ SERVICE as necessary.
at base idle was higher than expected. RERUN Quick Test.
- Air leaks between Vane Air Flow meter and fuel No ~ EEC system OK for
charging assembly metered air. GO to.
Quick Test to service
- Loss of ignition/fuel other codes if
Check for holes, cracks, and/or disconnections in necessary.
air cleaner outlet tube (between Vane Air Flow
meter and fuel charging assembly).
Check for loss of ignition or fuel on one or more
cylinder(s).
Are any faults present?

ALL RIGHTS RESERVED

KE
(Bypass Air) Test
..

HIGH ISC RPM
Service Code 16 indicates that with the ISC off, Yes ~ RESET throttle plate.
engine rpm was above a Self-Test limit. REFER to Section 4
Possible causes are: and VECI decal for
curb idle set procedure.
- Improper idle set RERUN Quick Test. If
- Purge solenoid Code 48 is still
- Air/vacuum leaks ,
present, GO to IKE21 I.
Is ~ode 48 present?
No ~ GO to IKD151.
KE2S1 SERVICE CODE 19:
LOW ISC RPM
Service Code 19 indicates that with the ISC off, Yes ~ INSPECT throttle body
engine rpm dropped below a Self-Test limit (usually and air inlet for
around 600 rpm). contamination.
Possible causes are: SERVICE as necessary.
If OK, ADJUST base
- Engine not at operating temperature.
idle (REFER to Section
- Throttle body/air inlet contamination. 4 for procedure).
- Improper idle set. RERUN Quick Test.
Key off.
Deactivate Self-Test. No ~ SERVICE other codes
Run engine at 2000 rpm for 2 minutes or. until as necessary.
inlet radiator hose is hot and pressurized.
Key off.
Does engine stumble and/or Is code 19 still
present?
.
I
LOW ISC RPM
Service Code 17 indicates that with the ISC off, Yes ~ INSPECT throttle body
~ngine rpm was below a Self-Test limit. and air inlet for
Possible causes are: contamination.
- Excessive engine accessory load If OK, ADJUST base
- Engine not at operating temperature idle (REFER to Section
- Throttle body/air inlet contamination 4 for procedure).
- Improper idle set RERUN Quick Test.
NOTE: Check and correct excessive' engine load
problems like cooling fan running, lights No ~ SERVICE other codes
on, etc. as necessary.
Run engine at 2000 rpm for 2 minutes or until
inlet radiator hose is hot and pressurized.
Key off.

ALL RIGHTS RESERVED
Electro Drive Fan (EDF)j Pinpoint

KF
High Electro Drive Fan (HEDF) Test
INote I
during 'Quick Test or you have been directed here from Diagnosis By Symptom.
IRemember I
Harness circuits: EDF, HEDF, EDF Power-To-Fan, HEDF Power-to-Fan, IGN Start/Run and
GND.
EDF Relay
HEDF Relay
Cooling Fan

ALL RIGHTS RESERVED
Electro Drive'Fan (EDF)/ Pinpoint

KF
High EI~ctro Drive Fan (HEDF) Test I

SHORT TO IGNITION
TO IGNITION CONNECTOR RELAY
START/RUN (SHORT FOR (BATT + IN START/RUN)
NON AlC)
r--- ------------,
I
EDF FAN I
RELAY (#1, N/C) I HEDF FAN
I RELAY (#2)
I
-TEST PIN 35 Gr YIW -EDF I
I
TEST PIN 31 0-R/BK -HEDF----I----..,....;..I-----41~-_~-__,
: HEDF
LG/Y -tPOWER-TO-FAN
COOLING AlC HIGH
FAN E F I PRESSURE
POWER ,
(1 STAGE FOR SWITCH
-TO- I BK
NON AlC (N/O)
FAN :
2 STAGE FOR
I
A/C) I
I
I WITH A/e
~-----------------------
BK
-:b-
TO IGNITION
_________ --- --I START/RUN
TEST
PIN 31 - - - - -............:.+~.........- - BATT (+)
HEDF FAN
RELAY (#2) TO
STARTER
A/C HIGH
PRESSURE
SWITCH (N/O)
1-= I
I
EDF FAN
RELAY (#1, N/C)
L...-----.f). TEST PIN
I
I 35
I
____~I!~ ~~ J
A13571A
"*TEST PINS LOCATED ON BREAKOUT BOX.

ALL RIGHTS RESERVED
17..292 EEC..IV Pinpoint Test Procedures

KF
KF1 SERVICE CODE 83/88:

CHECK FOR IGNITION START/RUN
CIRCUIT VOLTAGE AT HEDF/EDF RELAY
Service Code 83 indicates a HEDF primary circuit Yes ~ GO to JKF2!.

failure.
Service Code 88 indicates an EDF primary circuit No ~ SERVICE open circuit.
failure. RECONNECT EDF/
Possible causes are: HEDF relay. RERUN
- Open or shorted circuit. Quick Test.
- Faulty fan relay.
- Faulty processor.
- Faulty A/C high pressure switch (Code 83).
NOTE: During diagnosis, use the chart below to
determine the correct pin number, circuit
and relay being tested.
Test
Code Circuit Pin Fan Relay
Number
83 HEDF 31 HEDF(#2)
88 EDF 35 EDF( # 1)
Key off.
Disconnect EDF or HEDF relay.
Key on.
Measure voltage between IGN Start/Run circuit at
the EDF/HEDF relay vehicle harness connector
and chassis ground.
I

ALL RIGHTS RESERVED
Electro Drive Fan (EDF)/ Pinpoint

KF
High Electro Drive Fan (HEPF) Test
TE~T STEP RESULT ~ ACTION TO TAKE
KF21 ENTER OUTPUT STATE CHECK

. NOTE: Do not use STAR tester for this Step, Yes ~ REMAIN in Output
use VOM/DVOM. State Check. GO to
IKF31.
DVOM. on 20 volt scale. No ~ DEPRESS throttle to
WOT and RELEASE. If
Disconnect electrical connector on the speed STO voltage does not
control servo; if equipped. go high, leave
Connect DVOM negative test lead to STO at the equipment hooked up
Self-Test connector and positive test lead to the and GO to laC21.
battery positive post.
Jumper STI to SIG RTN at the Self:Test ..
connector.
Perform Key On Engine Off Self-Test until the
completion of the Continuous Memory Codes.
;
DVOM will indicate less than 1.0 volt when test
complete.
Depress and release throttle.
Does Yoltage increase to greater than 10.5
yoIts?
KF3 I CHECK FOR EDF/HEDF CIRCUIT CYCLING
Still in Outp~t State Check. Yes ~ REPLACE EDF or

HEDF relay. REMOVE
EDF or HEDF relay disconnected. jumper. RERUN Quick
DVOM on 20 volt scale. Test
Connect DVOM positive test lead to the IGN

No .~ REMOVE jumper. GO
Start/Run circuit and the negative test lead to the to IKF4/.
EDF or HEDF circuit at the EDF/HEDF relay
While observing DVOM, depress throttle. For EDF,
wait until "CHECK ENGINE" light flashes once (10
seconds). For HEDF, wait until "CHECK ENGINE"
light flashes twice (15 seconds). Release throttle.
EDF/HEDF outputs are now "on". To cycle "off",
depress and release throttle.
Does voltage cycle high and low (about 1 volt

change)?

ALL RIGHTS RESERVED

KF
KF4 I CHECK CONTINUITY OF EDF/HEDF CIRCUIT
Key off. Yes ~ GO to IKFSI.

EDF or HEDF relay disconnected.
Quick Test.
For Code 83:
- breakout box and HEDF circuit at the HEDF
relay vehicle harness connector.
For Code 88:
breakout box and EDF circuit at the EDF relay
Is resistance less than S.O ohms?
KFSI CHECK EDF/HEDF CIRCUIT FOR SHORT TO

POWER
Key on. Yes ~ GO to IKF61.

EDF or HEDF relay disconnected. REMOVE breakout box.
RECONNECT all
components. RERUN
Measure voltage between Test Pin 31 (HEDF) or Quick Test. If code is
35 (EDF) at the breakout box and battery still present, REPLACE
negative post. processor.

ALL RIGHTS RESERVED
Electro Drive Fan .(EDF)/ . 'Pinpoint

'KF
KF6 CHECK EDF/HEDF CIRCUIT FOR SHORT TO

GROUND

Breakout box installed, processor disconnected. RECONNECT all
EDF or HEDF relay disconnected. components. RERUN
Quick Test.
DVOM on 200,000. ohm scale.
Measure resistance between Test Pin 31 (HEDF) No ~ SERVICE short circuit.
or 35 (EDF) and Test Pins 40 and 60 at the (For Code 83, first
breakout box. VERIFY that AIC high
pressure switch is
Is resistance greater than 10,000 ohms? open). REMOVE
breakout box.
RECONNECT all
components. RERUN
Quick Test.
KF10 LOW SPEED (EDF) AND/OR HIGH SPEED

(HEDF) COOLING FAN DOES NOT OPERATE:
CHECK FOR VOLTAGE TO EDF RELAY
Key off. Yes ~ GO to IKF131.

Disconnect EDF relay.
No ~ For A/C equipped
DVOM on 20 volt scale. vehicles:
Keyon. GO to IKF111.
Measure voltage between the short connector
input pin at the EDF relay vehicle harness r
For non A/C vehicles:
connector and 'battery negative post.
VERIFY condition of
Is voltage greater than 10.5 volts? . jumper at short
connector and "
.- -
TO operation of IGN relay.
SHORT If OK, SERVICE open
CONNECTOR
h t
-- - ---,
circuit. RECONNECT
EDF relay.
., ._ TO HEDF I
... RELAY t
RE-EVALUATE
III I , symptom.
I
II IX)
I IXI; WITH AlC
1---- - I
J
EDFRELAY
VEHICLE HARNESS
CONNECTOR
A13572-A

ALL RIGHTS RESERVED

KF
KF11 I CHECK FOR VOLTAGE TO HEDF RELAY
Key off. Yes ~ GO to IKF121.

EDF relay disconnected.
Disconnect HEDF relay.
No ~ VERIFY operation of
IGN relay. If OK,
DVOM on 20 volt scale. SERVICE open circuit.
RECONNECT EDF and
Key on. HEDF relays.
Measure voltage between the IGN relay input pin RE-EVALUATE
at the HEDF relay vehicle harness connector and .symptoms.
TO
IGNITION
RELAY
ak
HEDFRELAY
VEHICLE HARNESS
CONNECTOR
A13573-A
KF121 CHECK CONTINUITY BETWEEN EDF AND

HEDF RELAYS
Key off. Yes ~ REPLACE HEDF relay.

RECONNECT all
EDF and HEDF relays disconnected.
components.
DVOM on 200 ohm scale. RE-EVALUATE
Measure resistance' between the HEDF input pin symptom.
~t the EDF relay vehicle harness connector and
the output to EDF pin at the HEDF relay vehicle No ~ SERVICE open circuit.
harness connector. RECONNECT EDF and
Is resistance less than 5.0 ohms? HEDF relays.
RE-EVALUATE
s.ymptom.
~ EDF
EIBJ
HEDF
RELAY
RELAY
VEHICLE HARNESS <;ONNECTORS
A13574-A

ALL RIGHTS RESERVED

KF
KF131 CHECK CIRCUITS FROM EDF RELAY TO FAN
Key off. Yes .. For A/C equipped

vehicles:
EDF relay disconnected. REMOVE jumper. GO
Insert jumper wire from short connector input pin to IKF161.
to Power-To-Fan pin at the EDF relay vehicle
For Non A/C
harness connector. vehicles:
Key on. REPLACE EDF relay.
REMOVE jumper.
Does fan run? RE-EVALUATE
symptom.
JUMPER No .. REMOVE jumper. GO

WIRE to IKF141.
EDFRELAY
A 13575-A
, KF141 CHECK EDF POWER-TO-FAN CIRCUIT

CONTINUITY
Key off. Yes .. GO to IKF1SI.

EDF' relay disconnected.
No .. SERVICE open circuit.
Disconnect cooling fan. RECONNECT all
components.
Measure resistance between the EDF Power-To- symptom.
Fan output pin at the EDF vehicle harness
connector and the EDF Power-To-Fan input pin at
the cooling fan vehicle harness connector.
~ POWER ~
~ TO ---J~=-r"\
EDF RELAY FAN. ~ III~ ~
~ =
COOLING FAN
A 13576-A

ALL RIGHTS RESERVED
Electro Drive Fan (EDF)/

High Electro Drive Fan (HEDF)
I Pinpoint
Test
I KF"
'-----_....
TEST STEP \
RESULT ~ ACTION TO TAKE
KF1S1 CHECK COOLING FAN GROUND CIRCUIT
Key off. Yes ~ REPLACE cooling fan.

RECONNECT all
EDF relay disconnected. components.
RE-EVALUATE
Cooling fan disconnected.
symptom.
.
Measure resistance between GND circuit at the No ~ SERVICE open circuit.
cooling fan vehicle harness connector and battery RECONNECT all
negative post. components.
RE-EVALUATE
Is resistance less than 5.0 ohms? symptom.
KF161 CHECK CIRCUITS FROM HEDF RELAY TO

FAN
Key off. Yes ~ REPLACE EDF relay.

REMOVE jumper.
EDF relay disconnected. RECONNECT AIC high
Disconnect AIC high pressure (A/C HP) switch. pressure switch.
RE-EVALUATE
Insert a jumper wire between the two pins of the symptom.
AIC HP switch vehicle harness connector.
Key on. No ~ REMOVE jumper.
RECONNECT EDF
Does fan run at high speed? relay. GO to IKF171.

ALL RIGHTS RESERVED
EECIV Pinpoint Test Procedures . 17299

KF
KF171 VERIFY CONTINUITY OF CIRCUITS FROM AIC

HIGH PRESSURE SWITCH
Key off.. Yes ~ GO to IKF1SI.

AIC HP switch disconnected.
Disconnect HEDF relay. RECONNECT all
components.
DVOM on 200 ohm' scale. RE-EVALUATE
Measure continuity from GND circuit at AIC HP symptom. If symptom is
switch vehicle harness connector and battery still present, continue
negative. post. diagnosis at IKF16\ .
Measure continuity between output to HEDF relay

pin at AIC HP switch vehicle harness connector
and AIC HP switch input pin at the HEDF relay
HEDF
RELAY
I
J I
-I><J
I I I
I
1 I
TEST PIN 31 0r-J....---_--- I
c:::lt
II II
I AlC HIGH
PRESSURE
~ ~ SWITCH

A13sn-A

ALL RIGHTS RESERVED

KF
KF181 CHECK HEDF POWER-TO-FAN VOLTAGE AT

FAN WITH AIC HP SWITCH GROUNDED .
Key off. Yes ~ REPLACE cooling fan.

REMOVE jumper.
AIC HP switch disconnected. RECONNECT all
Reconnect HEDF relay. components.
Disconnect cooling fan. RE-EVALUATE
symptom.
Again insert a jumper wire between the two pins
of the AIC HP switch vehicle harness connector.
No ~ REMOVE jumper.
RECONNECT AIC HP
Key on. switch. GO to IKF191.
Measure voltage between HEDF Power-To-Fan
circuit at the cooling fan vehicle harness
connector and battery negative post.
HEDF POWER-TO-FAN ~
COOLING FAN VEHICLE HARNESS CONNECTOR
A13578-A
KF191 CHECK HEDF POWER-TO-FAN CIRCUIT

CONTINUITY
Key off. Yes ~ REPLACE HEDF relay.

Cooling fan disconnected. RECONNECT all
components.
Disconnect HEDF relay. RE-EVALUATE
DVOM on 200 ohm scale. symptom.
Measure resistance between the HEDF Power-To-
Fan output pin at the HEDF vehicle harness No ~ SERVICE open circuit.
connector and the HEDF Power-To-Fan input pin RECONNECT all
at the cooling fan vehicle harness connector. components.
RE-EVALUATE
Is resistance less than 5.0 ohms? symptom.
ffi.j"- HEDF POWER-TO-FAN
HEDF RELAY
A13579-A

ALL RIGHTS RESERVED
Electro Drive' Fan (EDF)j Pinpoint

KF

~
KF25 LOW SPEED (EDF) OR HIGH SPEED (HEDF)

COOLING FAN ALWAYS ON:
VERIFY IGNITION RELAY IS OPENING
NOTE: Verify that A/C is off during testing. Yes ~ VERIFY that IGN relay
contacts are not
Is coollng.. fan always on with key off, but always closed. If OK,
operating normally with key on? CHECK circuit from
IGN relay to fan .
relay(s) for short to
BATT(+).
"
t
No \
~ "GO to IKF261.
KF26 CHECK FOR EDF RELAY ALWAYS CLOSED
Key off. Yes ~ For A/C equipped

vehicles:
Disconnect EDF relay. I
GO to I KF271.
Key on.
. Does fan continue to run? For non A/C vehicles:
SERVICE short to
power in EDF
Power-To-Fan circuit.
RECONNECT EDF
relay. RE-EVALUATE
symptom.
No ~ REPLACE EDF relay.

RE-EVALUATE
symptom.
KF27 CHECK HEDF RELAY
Key off. Yes ~ GO to IKF2S1 .

EDF relay disconnected.
No ~ REPLACE HEDF relay.
Disconnect HEDF relay. RECONNECT EDF
relay. RE-EVALUATE
Key on. symptom.
Does fan continue to run?

ALL RIGHTS RESERVED
Electro Drive Fan (EDF)j Pinpoint I KF

'--------
I
KF28 CHECK EDF POWER-TO-FAN CIRCUIT FOR
SHORT TO POWER
Key off. Yes ~ .SERVICE Short-To-

Power in EDF Power-
EDF and HEDF relay disconnected. To-Fan circuit.
RECONNECT all
Disconnect cooling fan.
components.
DVOM on 20 volt scale. RE-EVALUATE
symptom.
Key on.
Measure voltage between EDF Power-To-Fan No ~ SERVICE Short-To-
circuit at the cooling fan vehicle harness Power in HEDF Power-
connector and battery negative post. To-Fan circuit.
RECONNECT all
Is voltage greater than 1.0 volt? components.
RE-EVALUATE
EDF POWER-TO-FAN symptom.
/" ~
HEDF POWER-TO-FAN ~ I I ~
~I
~
COOliNG FAN VEHICLE HARNESS CONNECTOR
A13580-A

ALL RIGHTS RESERVED
EECIV Pinpoint Test Procedures ,17-303
IService Pin Adjustment Pinpoint

'Test
KH
INote I
during ,:Quick Test or from Diagnosis By Symptom.
IRemember I
Harness circuits: Octane Adjust, Idle Adjust
Service Pin Connector Shell (Jumper Wire)
IPinpoint Test Schematic I.

SERVICE PIN
CONNECTOR
TEST PIN 230---

TO ENGINE
BLOCK GROUND
TEST PIN 280- BR-IDLE ADJUST ~~9J
SERVICE PIN
VEHICLE
CONNECTOR
HARNESS
(JUMPER WIRE)
CONNECTOR
A13536-A

ALL RIGHTS RESERVED
l_s_e_IVl_-c_e_p_iD_A_d_i_u_s_tm_e_D_t 11 Pi;:::nt '---_K_H_---'

I
KH1 CHECK IF THE OCTANE ADJUST SERVICE

WIRE IS INSTALLED
Service Code 57 is not a fault code but an Yes ~ Service Code 57

"information" code (exclusive on Scorpio) indicating indicates service pin in
that Service Pin 23 jumper wire is installed or the use. Do not remove.
circuit is shorted to ground. If additional information Testing complete.
is iegUirjd on the Octane Adjust service pin, refer
to KH3 . No ~ GO to IKH21.
Locate the 3-pin service connector.
Is Jumper wire installed for Service Pin 23?
KH2 CHECK FOR SHORT TO GROUND

Install breakout box, leave processor disconnected. No ~ SERVICE short to
Measure resistance between Test Pin 23 and Test ground. REMOVE
Pins 20, 40 and 60 at the breakout box. breakout box. RERUN
Quick Test.
KH3 OCTANE ADJUST PIN
The purpose of the Octane Adjust is to produce

effective combustion using optimum spark
advance. .
If the vehicle spark knocks, add a jumper wire
from the Octane Adjust circuit of the 3-way
service pin connector to the engine block eyelit
ground. This will retard spark an additional 4
degrees. Also, a KOEO Service Code 57 will be
displayed to indicate that this service pin is in
use.
If the vehicle' continues to detonate (spark knock)
use a higher octane grade of fuel.
SERVICE
PIN CONNECTOR
A13581-A

ALL RIGHTS RESERVED
EEe-IV Pinpoint Test Procedures 17-,305
l_s_e_IVI_-c_e_P_iD_'_A_d_j_u_s_tm_e_D_t ~~---JI _P_i;_:_:_:_D_t--'

L..-'
K
_"_---'
L..-_
KH10 CHECK IF THE IDLE ADJUST SERVICE WIRE

IS INSTALLED
Service Code 59 is not a fault code but an . Yes .~ Service Code 59

"infprmation" code (exclusive on Scorpio) indicating indicates service pin in
that Service Pin 28 jumper wire is installed or the use. Do not remove.
circuit is shorted to ground. If additional information Testing complete.
,is req,ired on the Idle Adjust service pin, refer to
KH12 . ~ . GO to I KH111 .
No
Locate the 3-pin service connector:
Is jumper wire installed for Service Pin 28?
KH11 CHECK FOR SHORT TO GROUND

RERUN Quick Test.
Measure resistance between Test Pin 28 and Test ground. REMOVE
Pins 20, 40 and 60 at the breakout box. breakout box. RERUN
Is each resistance greater than 10,000 ohms? Quick Test.
KH12 IDLE ADJUST PIN
The purpose of the Idle Adjust circuit is to

increase vehicle rpm due to additional engine
loads.
If the vehicle's curb idle appears to be low during
parking maneuvers or vehicle stalls while AlC is on,
add a jumper wire from the Idle Adjust circuit oLthe
3-way service pin connector to the engine block eyelit
ground. This will increase idle by 50 rpms in drive.
Also, a KOEO Service Code 59 will be displayed to
indicate that this service pin is in use.
If vehicle continues to exhibit drive concern, go to

Idle Adjust procedure in Section 4.
SERVICE
PIN CONNECTOR
A13581-A

ALL RIGHTS RESERVED
Shift Indicator Light [ Pinpoint I KL

(SIL) Test
'--------
INote I
Diagnosis By Symptom or Pinpoint Test Step IQA91.
IRemember I
Harness circuits: SI Land STO
Top Gear Switch
SIL Dimmer Relay
SIL Bulb and SIL circuit fuse

1.9L EFI
J.P. SHIFT INDICATOR

LIGHT
TO
TEST PIN 17@- T/LB SIL (3)1 .....- - 1 . IGNITION
RUN
CKT.
TOP GEAR I I
SWo 1 ennl' H2) ~ TO RUNNING
L ...J(1) ~
LIGHT SWITCH
STO SIL DIMMER RELAY

(LOCATED BEHIND GLOVE BOX)
STO SELF-TEST
CONNECTOR
SIGNAL
JII~':::;f#I'
II
RETURN SELF TEST INPUT
CONNECTOR (STI)
~ g
DIMMER RELAY VEHICLE
HARNESS CONNECTOR
A9681-E

ALL RIGHTS RESERVED
Shift Indicator Ligh.t Pinpoint

KL
(SIL) Test

1.9L MA SEFI
TEST PIN 53 ~LG/R--SIL-@f----I _I TO IGNITION

RUN CKT
1.0. SHIFT TOP
INDICATOR GEAR
LIGHT SW
*TEST PINS LOCATED ON BREAKOUT BOX. A13607-A
ALL OTHERS
TESTPIN530-SIL~
~
TEST PIN 51 (1.9L CFI) . TOP GEAR

3
(~I
r: - - - - -
~
L.-..-J :
IP SHIFT
INDICATOR
LIGHT
1(5)
e
TO
IGNITION
RUN
CKT
QI;
. .' SW TO RUNNING
I ~. 1(2) .. LIGHT SWITCH
L -.J(1) ~
SIL DIMMER RELAY 2 3
(LOCATED BEHIND GLOVE COMPARTMENT) ---
- . DIMMER RELAY VEHICLE
*TEST PINS LOCATED ON BREAKOUT BOX. HARNESS CONNECTOR
ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A96SG-E
Test Pin Application Wire Color

51 1.9L CFI T/LB
2.3L HSC 0
53
3.8L SC P

ALL RIGHTS RESERVED
Shift Indicator Light

(SIL)
I Pinpoint
Test
I KL
"-----_......
KL1 I CHECK SIL OPERATION
NOTE: To verify SIL operation, observe the SIL Yes ~ For 1.9L MA SEFI:
while driving the vehicle. The SIL should GOtoIKL101.
oJ
turn on when the optimum shift speed is
reached in each gear and remain off For all others:
while in the highest gear. GO to IKL61.
If the SI L is always on, look for a short to ground
in the SIL circuit. If the SIL is always off, look for No ~ GO to IKL21.
an open in the SIL circuit.
Is SIL on all the time?
KL2 I CHECK SIL CIRCUIT FUSE
Key off, wait 10 seconds. Yes ~ RECONNECT SIL

circuit fuse. GO to
Remove .SIL circuit fuse (# 18 for all except 1.9L
MA) and inspect. IKL31.
Is fuse OK?
ground between SI L
circuit fuse and SIL
bulb. REPLACE SIL
circuit fuse. VERIFY
SIL operation.
KL3 I CHECK SIL BULB
Key off. Yes ~ For 1.9L MA SEFI:

Remove SI L bulb and inspect. GO to IKL1s1 .
Is SIL bulb OK? For all others:

RECONNECT SIL bulb.
GO to IKL41.
No ~ REPLACE SIL bulb.

VERIFY SIL operation.
KL41 CHECK SIL DIMMER RELAY

CONTINUITY
Key off. Yes ~ GO to IKLSI.

Disconnect SIL dimmer relay.
DVOM on 200 ohm scale. No ~ REPLACE SIL dimmer
relay. VERIFY SIL
Measure resistance between pins 3 and 5 on SI L operation.
dimmer relay.

ALL RIGHTS RESERVED
Shift Indicator Light Pinpoint

KL
(SIL) Test
KL5 I CHECK SIL DIMMER RELAY FUNCTION
Key off. Yes ~ GO to IKL61.

SIL dimmer relay disconnected.
Apply 12 volts across pins 1 and 2 on the SI L
No ~ REPLACE SIL dimmer
relay. VERIFY SIL
dimmer relay.
operation.
Measure resistance between pins 3 and 5 on SI L
dimmer relay.
Is resistance between 40 ohms and 55 ohms?
KL61 CHECK VOLTAGE AT'SIL DIMMER

RELAY ,
Key on, engine off. Yes ~ RECONNECT SIL

dimmer relay. GO' to
Disconnect SIL dimmer relay.
,
IKL71.
Measure voltage between pin 5 on the SIL No ~ SERVICE circuit
dimmer relay vehicle harness connector and the between SI L dimmer
battery negative post. relay and SI L fuse.
Is voltage greater than' 5 volts? VERIFY SIL operation.
KL71 CHECK VOLTAGE AT TOP GEAR

SWITCH
l
Key on, engine off. Yes ~ GO to IKLSI.

1
Disconnect top gear switch.

DVOM on 20 volt scale. No ~ SERVICE circuit
between top gear
Measure voltage between the SI L dimmer relay switch and SIL dimmer
side of the top gear switch vehicle harness relaY. VERIFY SIL
connector and the battery negative post. operation.
Is voltage greater than, 5 volts?
KL8 I CHECK OPERATION OF TOP GEAR SWITCH
Key off, wait 10 seconds. Yes ~ GO to IKL91.

Top gear switch disconnected.
No ~ REPLACE top gear
switch. VERIFY SIL
Measure resistance of top gear switch while operation.
shifting the transmission from the highest gear to
the next lower gear.
Does circuit open and close?

ALL RIGHTS RESERVED
Shift Indicator Light Pinpoint

KL
(SIL) Test
TEST STEP RESULT .~ ACTION TO TAKE
KL9 I CHECK CONTINUITY OF SIL CIRCUIT

Top gear switch disconnected.
No ~ SERVICE open circuit
Disconnect processor 60 pin connector. Inspect between the top gear
for damaged or pushed out pins, corrosion, loose switch and the
wires, etc. Service as necessary. processor. REMOVE
breakout box.
DVOM on 200 ohm scale. components. VERIFY
SIL operation.
51 on 1.9L CFI or Test Pin 17 on 1.9L EFI) at
the breakout box and the processor side of the
top gear switch vehicle harness connector.
I
KL10 CHECK SIL CIRCUIT FOR SHORT TO GROUND

Reconnect top gear switch (if applicable). RERUN Quick Test.
Shift transmission to highest gear.
ground between top
DVOM on 200,000 ohm scale. gear switch and
processor (on 1.9L EFI,
Measure resistance between Test Pin 53 (Test Pin also CHECK STO
51 on 1.9L CFI or Test Pin 17 on 1.9L EFI) and circuit for short to
Test Pin 60 at the breakout box. ground). REMOVE
breakout box.
Is resistance greater than 10,000 ohms? RECONNECT
processor. VERIFY SIL
operation.

ALL RIGHTS RESERVED
EEC-IV Pinpoint Test Procedu~s 17-311
Shift Indicator Light Pinpoin~

KL
(SIL) Test
KL151 CHECK FOR VOLTAGE TO SIL SOCKET

SIL bulb removed.
No ~ RECONNECT SIL bulb.
Transmission in any gear except top gear. GO to IKL161.
- .
Key on, engine off.
Measure voltage between power contact at SIL
socket and chassis ground.
KL161 CHECK OPERATION OF TOP GEAR SWITCH
NOTE: The Top Gear switch is a normally closed Yes ~ SERVICE open in
switch and is in the ignition RUN circuit ignition run circuit to
to the SIL bulb. The Top Gear switch the SIL bulb socket.
should be open only when the vehicle is VERIFY SIL operation.
shifted to top gear.
Key off.
No ~ REPLACE Top Gear
switch. VERIFY SIL
Transmission in any gear except top gear. operation.
Disconnect Top Gear switch.
Measure resistance of the Top Gear switch.
KL171 CHECK CONTINUITY OF SIL CIRCUIT

I
SIL bulb removed. RECONNECT SIL bulb.
Disconnect processor 60 pin connector. Inspect VERIFY SIL operation.
wires, etc. Service as necessary. No ~ SERVICE open circuit.
Install breakout box, leave processor disconnected: RECONNECT all
DVOM on 200 ohm scale. components. VERIFY
SI L operation.
breakout box and SIL circuit contact at the SIL
bulb socket.

ALL RIGHTS RESERVED
WOT AIC Cutout (WAC) Pinpoint

KM
AIC Demand Test
INote I
You should enter this Pinpoint Test only when directed here from Diagnosis By
Symptom.
IRemember I
may be at fault:
Refrigerant charge
Ambient temperature less than 45
Harness circuits: WAC, VPWR, GNO, POWER-TO-CLUTCH, ACO
WAC relay (-11433- or -13A025-) or A/C fan controller (-8C619-)

ALL RIGHTS RESERVED
VVOT Ale Cutout (VVAC) Pinpoint

Test
KM
AIC Demand

3.8l SEFI RWD, S.Ol SEFI MARK VII, S.Ol SEFI MA MUSTANG, 2.9L TRUCK, 3.0l
EFI TRUCK, 4.0l TRUCK
WAC RELAY TO AlC

HARNESS
CONNECTOR. ~-t--~ DEMAND SWITCH
TEST PIN 1 0 0 ' A C C S - - - - - - -.. AlCCLUTCH
CYCLIC
PRESSURE
SWITCH
~VPWR
TEST PIN 37 TEST PIN 54
TESTPIN57~ _ _ WAC
POWER-TO- . TO
CLUTCH RELAY
VPWR~----fol~~
(NORMALLY
TEST PIN 54 0 WAC-----t---- .- .....--+... CLOSED)
TEST PIN 10
AlCCLUTCH
AlC CYCLIC AIC
CLUTCH PRESSURE CLUTCH
SWITCH
TO AlC
DEMAND
SWITCH
A11536-B
Test Pin 10 ACCS

Application Color
3.8L SEFI RWD
PK/LB
5.0L SEFI MA
2.9L Truck , T/Y
4.0L RangerIBronco II
3.0L EFI Truck
BK/Y
4.0L Aerostar
5.0L SEFI LG/P
Test Pin 54 WAC

Application Color
3.8L SEFI RWD
5.0L SEFI O/LB
5.0L SEFI MA
2.9L Truck P
3.0L EFI Truck GY/W

ALL RIGHTS RESERVED
WOT AIC Cutout (WAC) I Pinpoint I KM

AIC Demand Test L...- .....

2.3L TRUCK
WAC RELAY
HARNESS CONNECTOR TOAIC
TEST PIN 43 LG/P ACD DEMAND
AlCCLUTCH SWITCH
CYCLIC
PRESSURE WAC
TEST PIN 10 0 TIY A C C S - - - - -.. SWITCH TEST PIN 54 RELAY
(NORMALLY
TEST PIN 37 e-, CLOSED)
TEST PIN 57 ~VPWR--+--n TO

VPWR . .--~~-..
TEST PIN 54 0 P WAC ----1-- TEST

POWER- PIN 10
TO-
NC CiL AlC
CLUTCH ~ CLUTCH
TOAIC
DEMAND
SWITCH A11537B
1.9L CFI, 1.9L EFI
AlC FAN CONTROLLER

HARNESS CONNECTOR
TEST PIN 54 0_.....;O_/L_B _
TEST PIN 10 _ _ ACC ......---..-oM.

0~_B_KlY
POWER-TO- TO AlC
CLUTCH _;.;..;..--+.....~....._LG~/~ DEMAND
~~UTCH~
10 AlC CLUTCH SWITCH
CYCLIC
GYIY PRESSURE
SWITCH
TO IGNITION
SWITCH RUN
CIRCUIT
A11538C

ALL RIGHTS RESERVED
WQT AIC Cutout (WAC) Pinpoint

KM
AIC Demand Test

2.3L HSC EFI
AlC FAN CONTROLLER

HARNESS CONNECTOR
TEST PIN 54 0 __0_/L_B_ _WAC ---N"I
TO IGNITION SWITCH POWERTO-CLUTCH

RUN CIRCUIT BKN
TEST PIN 10 G> TN ACCS~_---IK1 AlC
CLUTCH
AlCClUTCH
CYCLIC
PRESSURE
SWITCH
TEST PIN 430 LGI P ACD
TO AlC
DEMAND
SWITCH
A11539C
2.3L MA EFI CAR, 2.3L OHC EFI CAR
TO AIC FAN CONTROLLER

BATT (+) HARNESS CONNECTOR
TEST PIN 54 0 OILB WAC--------t-t

TOAIC BK
DEMANDSW
TEST PIN 24 (!)~ __

(TEST PIN 43
GYIY TO IGNITION SWITCH

RUN CIRCUIT
8
POWER
- - - - -.. TO
CLUTCH
AlC
CLUTCH
A13554A

ALL RIGHTS RESERVED
17-316 EEC-IV Pinpoint Test Pro.cedures
WOT AIC Cutout (WAC) Pinpoint I KM

AIC Demand' Test
'---------'

5.0L SEFI TOWN CAR, CROWN VICTORIA/GRAND MARQUIS
5.0L SEFI MA TOWN CAR, CROWN VICTORIA/GRAND MARQUIS
TO AIC
DEMAND
SWITCH
AIC CLUTCH
CYCLIC PRESSURE
SHORTING PLUG SWITCH
(WITHOUT HEATED
WINDSHIELD ONLY)
0-- ACCS -----~-_f_I_+-~
,,
TEST PIN 10
, HEATED
: WINDSHIELD
: ONLY
HEATED WINDSHIELD : ,..-.-------JL..,
CONTROL MODULE ,
,-----~I
TEST PIN 37 0 - - R _ _L_-_- - - -- - - __ I
TEST PIN 57 0 - - R - - -......-VPWR -t---....,
POWER
TO
CLUTCH
AIC CLUTCH
A13555A

Town Car PK
All Others PK/LB

ALL RIGHTS RESERVED
EEC'V Pinpoint Test Procedures 17317
W9T AIC Cutout (WAC) Pinpoint

KM
AIC Demand Test
IPinpoint Test Schematic I.

1.9L MA SEFI
TEST PIN 54 0-BLlBK-WAC - - - - - . . . . . . . . ,
TEST PIN 10 @-GR/BK-ACC_e_------.

WAC
RELAY
HARNESS
CONNECTOR
FROM
AlC'
RELAY POWER TEST TOIGN
TO
L
PIN 10 RUN .-
CLUTCH
TO ..
BATT (+). GR/BK .A/C
CLUTCH
[OPJCRRAY
L~LlY
AIC
RELAY
BLlGR+
TO IGN RUN
TO
I
BATT (+) I
TO
L.P. SWITCH,
HARNESS
ETC.
CONNECTOR
BLOWER
MOTOR
SWITCH ~ ......
A13556-A

ALL RIGHTS RESERVED

KM.
AIC Demand Test

2.9L EFI SCORPIO
IGNITION
START/RUN
~
EATC
MODULE
:~S_E B.-~Y
BKIW
BK/R
~
!'i~ TOA/C
AlC DE-ICING
L
DE-ICING
SWITCH
(NORMALLY ~ ~) SWITCH
OPEN)
~~ y TEST PIN
37/57 TEST
TEST PIN 10 0-BKIY--AC BR
. ~ PIN
BK BKIY 10
TEST PIN 37 0,
TEST PIN 57 ~BK _ _ VPWR J.. -Lr
OI'
BKlY WAC
TEST PIN 54 0-BR/GN-WAC ~ WAC RELAY

VEHICLE HARNESS
RELAY
(NORMALLY
CLOSED)
CONNECTOR r
BR/GN
BKlY
~tST
I
POWER
TO B1K/Y
CLUTCH
54
THREE-WAY
PRESSURE TO
SWITCH THREE-WAY
[}] PRESSURE
SWITCH
'Y
BK/Y
rrt,
f.-1tJ
AIC
CLUTCH
A13557-A

ALL RIGHTS RESERVED

KM
AIC Demand Test
KM1 ICLUTCH
NO A/C: CHECK FOR VOLTAGE AT AIC
NOTE: Before proceeding with "NO A/C" Yes ~ EEC-IV system OK.
diagnostics, verify integrity of related Refer to Ventilationl
fuses in fuse panel. . Climate Control Shop
Manual Group AIC
Key .off. Diagnosis, to check for
poor ground, open
Disconnect AIC clutch. circuit in clutch,
AIC demand switch to A/C. mechanical problems,
etc.
For 1.9L MA SEFI, turn blower motor switch on
(any speed). No ~ GO to IKM21.
Start engine, wait 10 seconds.
Measure voltage between the power side of the
AIC clutch vehicle harness connector and battery
negative post.
KM21 CHECK POWER-TO-CLUTCH CIRCUIT

CONTINUITY
NOTE: Applications with WAC relay: 1.9L MA Yes ~ RECONNECT AIC

SEFI, 2.9L EFI Car, 3.8L SEFI RWD, 5.0L clutch. GO to IKM31 .
SEFI, 5.0L SEFI MA, 2.3L TRK, 2.9L TRK,
3.0L EFI TRK, 4.0L TRK. No ~ For 2.9L EFI CAR:
Applications with AIC fan controller: 1.9L VERIFY operation of
CFI, 1.9L EFI, 2.3L car. Three-Way Pressure
switch. REFER to
. Key off. VentilatinglClimate .
Control Group in Shop
AIC clutch disconnected. Manual, AIC Diagnosis.
Disconnect WAC relay or AIC fan controller. If OK, SERVICE open
circuit. RECONNECT all
RE-EVALUATE
Measure resistance between power side of the symptom.
AIC clutch vehicle harness connector and
POWER-TO-CLUTCH pin at the WAC relay or AIC For all others:
fan controller vehicle harness connector.
SERVICE open circuit.
Is resistance less than 5.0 ohms? RECONNECT all
components.
RE-EVALUATE
symptom.

ALL RIGHTS RESERVED
17..320 EECIV Pinpoint Test Procedures

KM
AIC Demand Test
KM31 CHECK FOR POWER ON AIC DEMAND

CIRCUIT
Key on, engine off. Yes ~ GO to IKM61.

WAC relay or AIC fan controller disconnected.
No ~ For 2.9L EFI Car:
AIC demand switch to A/C. GO to IKM41.
DVOM on 20 volt scale. For 1.9L MA SEFI:
For 2.9L EFt Car: GO to IKMSI.
- Measure voltage between AIC De-icing switch For all others:
input at WAC relay vehicle harness connector VERIFY operation of
and chassis ground. AIC clutch cyclic
pressure switch and
For 1.9L MA SEFI: AIC demand switch.
- Blower motor switch on (any speed). REFER to Ventilationl
- Measure voltage between AIC relay input pin at Manual Group. If OK,
WAC relay vehicle harness connector and SERVICE open circuit.
chassis ground. RECONNECT all
components.
All Others: RE-EVALUATE
symptom.
- Measure voltage between AIC demand input pin
at WAC relay or AIC fan controller vehicle
harness connector and chassis ground.
0:

ALL RIGHTS RESERVED

KM
AIC Demand Test
KM4 CHECK CONTINUITY BETWEEN WAC REL:.AY

AND AIC DE-ICING SWITCH
Key off. Yes RECONNECT WAC

relay. REFER to
WAC relay disconnected. VentilationlClimate
Disconnect AIC De-icing switch~ Control Shop Manual
Group to check for
DVOM on 200 ohm scale. voltage to A/C De-icing
Measure continuity between the AIC De-icing .' . switch from ignition
switch' output to the WAC relay at the AIC De- switch, proper
icing switch vehicle harness connector and the grounding and
AIC De-icing switch input at the WAC relay operation of AIC De-
vehicle harness connector. icing switch, proper
input from the EATC
Is resistance less than 5.0 ohms? module, etc.
No SERVICE open circuit.

"'--------------- RECONNECT WAC
relay and A/C De-icing
switch. RE-EVALUATE
symptom. .
A13558-A
. ~GND(BR)
10 WAC RELAY (BKIY)
IGNITION STAAT/RUN (BKIW)
EATC MODULE (BKIW)
AlC DEICING SWITCH HARNESS CONNECTOR
NOTE: THE AlC DE-ICING SWITCH IS A ; \

NORMALLY OPEN RELAY A9199.B
~
POWER-IO-CLUTCH
. . FROM AlC DE-ICING SWITCH
- WAC
VPWR
WIDE OPEN THROnLE AlC CUTOUT (WAC)

RELAY HARNESS CONNECTOR
A92OG-B

ALL RIGHTS RESERVED

KM
AIC Demand Test
KM51 CHECK CONTINUITY BETWEEN WAC RELAY

AND AIC RELAY
Key off. Yes ~ RECONNECT WAC

relay. REFER to
WAC relay disconnected. VentilationlClimate
Disconnect AIC relay. Control Shop Manual
Group to check for
DVOM on 200 ohm scale. proper input to AIC
Measure resistance between the AIC relay output relay from BATT(+),
to the WAC relay at the AIC relay vehicle IGN RUN and AIC
harness connector and the AIC relay input at the demand circuits; proper
WAC relay vehicle harn~ss connector. AIC relay operation,
etc.
RECONNECT WAC
relay and AIC relay.
KM61 CHECK WAC CIRCUIT FOR SHORT TO

GROUND
Key off. Yes ~ For AIC fan

controller
WAC relay or AIC fan controller disconnected. applications:
Disconnect processor 60 pin connector. Inspect GO to IKM71.
wires, etc. Service as necessary. Leave processor For WAC relay
disconnected. applications:
GO to IKM91.
. Measure resistance between WAC circuit at the
WAC relay or AIC fan controller harness
RECONNECT all
connector and chassis ground. components.
Is resistance greater than 10,000 ohms? RE-EVALUATE
symptom.
KM71 CHECK FOR GROUND TO AIC FAN

CONTROLLER
Key off. Yes ~ GO to IKMSI.

AIC fan controller disconnected.
RECONNECT all
RE-EVALUATE
Measure resistance between ground circuit at AIC symptom.
fan controller vehicle harness connector and
chassis ground.

ALL RIGHTS RESERVED

KM
AIC Demand Test
KMSI CHECK FOR VOLTAGE TO AIC FAN

CONTROLLER
Key on. Yes ~ GO to IKM9'1 .

AIC fan controller disconnected.
Processor disconnected. RECONNECT all
components.
Measure voltage between ignition switch RUN symptom.
~
circuit at the AIC fan controller vehicle harness

connector and chassis ground.
Measure voltage between SATI( +) circuit at the
A/C fan controller vehicle harness connector and
chassis ground.
Are both Yoltages greater than 10.5 Yolts?
KM91 CHECK WAC RELAY, A/C FAN CONTROLLER

RECONNECT A/C
Processor disconnected. clutch. RE-EVALUATE
.. symptom.
Reconnect WAC relay or AIC fan controller.
Disconnect AIC clutch.
- No ~ REPLACE WAC relay
DVOM on 20 volt scale. or A/C fan controller.
RECONNECT all
Key on, engine off. compounds.
RE-EVALUATE
AIC demand switch to A/C. symptom. ,
For 1.9L MA SEFI turn blower motor switch on
(any speed).
Measure voltage between the power side of the
A/C clutch vehicle harness connector and the
.
. Is Yoltage greater than 10.5 Yolts?
,

ALL RIGHTS RESERVED
WOT AIC Cutout (WAC) I Pinpoint I KM

AIC Demand Test 1...- ......
KM15 NO AIC CUTOUT AT WOT: ENTER

OUTPUT STATE CHECK (REFER TO
IKM161.
DVOM on 20 'volt scale. No ~ DEPRESS throttle to
Disconnect electrical connector on the Speed WOT and RELEASE. If
Control servo; if equipped. STO voltage does not
go high, leave
Connect DVOM negative test lead to STO at the equipment hooked up
Self-Test connector and positive test lead to and GO to~oint
battery positive po~t. Test Step QC2 .
Jumper STI to SIGNAL RETURN at the Self-Test
connector.
completion of the Continuous Memory Codes.
DVOM will indicate less than 1.0 volt when tes'~
complete.
Does Yoltage increase to greater than 10.5
Yolts?
KM16 WAC RELAY OR AIC FAN CONTROLLER
WAC relay applications: 1.9L MA SEFI, 2.9L EFI WAC relay ~ GO to IKM 171 .
Car, 3.8L SEFI RWD, 5.0L SEFI, 5.0L SEFI MA,
2.3L TRK, 2.9L TRK, 3.0L EFI TRK, 4.0L TRK. AIC fan ~ GO to 1KM221.
AIC fan controller applications: 1.9L CFI, 1.9L controller
EFI, 2.3L car.
KM17 CHECK FOR VPWR TO RELAY
Still in Output State Check. Yes ~ GO to 1KM1SI.

Disconnect harness from WAC relay.
DVOM on 20 volt scale. VPWR circuit between
Measure voltage between VPWR circuit (IGN RUN power relay and WAC
for 1.9L MA SEFI) at the WAC relay vehicle relay (for 1.9L MA
harness connector and chassis ground. SEFI, IGN RUN circuit
between WAC relay
Is Yoltage greater than 10.5 Yolts? and joint box).
RECONNECT all
components and
REMOVE jumper.
REEVALUATE
symptom.

ALL RIGHTS RESERVED

KM
AIC Demand Test
KM1S1 CHECK FOR WAC CYCLING
Still in Output State Check. Yes ~ REPLACE WAC relay.

REMOVE jumper.
Reconnect WAC relay. RE-EVALUATE
symptom.
Connect DVOM positive test lead to the VPWR
circuit (IGN RUN for 1.9L MA SEFI) and the
No ~ REMOVE jumper.
RECONNECT Speed
negative test lead to the WAC circuit at the WAC Control servo. GO to
relay vehicle harness connector. IKM191.
While observing DVOM, depress and release
throttle several times (to cycle output on and off).
Does voltage cycle high and low?
KM191 CHECK WAC CIRCUIT CONTINUITY
Key off. Yes ~ GO to IKM201.

Install breakout box, leave processor disconnected. components.
RE-EVALUATE
Disconnect WAC relay. symptom.
breakout box and WAC circuit at the WAC relay

POWER

RECONNECT WAC
Breakout box installed, processor disconnected. relay. REEVALUATE
WAC relay disconnected. symptom.
DVOM on 200,000 ohm scale. No ~ SERVICE short circuit.

Measure resistance between Test Pin 54 and Test REMOVE breakout box.
components.
Are both resistances greater than 10,000 RE-EVALUATE
ohms? symptom. IF symptom
is still present,
REPLACE processor.

ALL RIGHTS RESERVED

KM
AIC Demand Test
KM221 CHECK FOR WAC CYCLING
Still in output state check. Yes ~ REPLACE AIC fan

controller. REMOVE
Disconnect AIC fan controller. jumper. RECONNECT
Speed Control servo.
Connect DVOM positive test lead to the Ignition symptom.
Run circuit and the negative test lead to the WAC
circuit at the AIC fan controller vehicle harness No ~ REMOVE jumper.
connector. RECONNECT Speed
Control servo. GO to
While observing DVOM, depress and release IKM231.
throttle several times (to cycle output on and off).
Does voltage cycle high and low?
KM231 CHECK WAC CIRCUIT CONTINUITY
Key off. Yes ~ GO to IKM241.

wires, etc. Service as necessary. RECONNECT processor
Install breakout box, leave processor disconnected. and AIC fan controller.
RE-EVALUATE
AIC fan controller disconnected. symptom.
breakout box and WAC circuit at the WAC relay

POWER

RECONNECT AIC fan
B~eakout box installed, processor disconnected. controller.
AIC fan controller disconnected. RE-EVALUATE
symptom.
Pins ~7 and 57 at the breakout box. REMOVE breakout box.
RECONNECT processor
Are both resistances greater than 10,000 and AIC fan controller.
ohms? RE-EVALUATE
symptom. If symptom is
still present, REPLACE
processor.

ALL RIGHTS RESERVED

KM
AIC Demand Test
KM301 CYCLE A/C DEMAND .SWITCH

Yes . REPLACE processor.
RERUN Quick Test.
Install breakout box, leave processor disconnected. No ~ GO to I KM31 I.
Key on, engine off.
Connect DVOM positive test lead to Test Pin 43
(Test Pin 24 for 2.3L OHC EFI) and negative test
lead to Test Pin 40.
Does voltage cycle high and low when Ale
demand switch is cycled?
KM311 CHECK ACD CIRCUIT CONTINUITY

,
Key off, wait 10 seconds. Yes ... SERVICE open in ACD

circuit. REMOVE
breakout box.
DVOM on 200 ohm scale. RECONNECT
Measure resistance between Test Pin 43 Crest Pin processor. RERUN
. 24 for 2.3L OHC EFI) at the breakout box and
A/C demand switch.
Is resistance greater than S ohms? No . Quick Test.
EEC-IV system OK.

,

RECONNECT
processor. REFER to
Ventilation/Climate
Control Group in Shop
Manual.
KM3S1 CHECK ACD CIRCUIT FOR SHORT TO POWER
Key off..
Yes
,
. EEC-IV system OK.
RECONNECT all
wires, etc. ~ervice as necessary. components. REFER to
Ventilation/Climate
Install breakout box, leave processor disconnected. Control Group in Shop
Disconnect WAC relay (TRK) or A/C fan controller
(CAR).
A/C demand switch "OFF".
No . Manual.
VERIFY operation of
A/C demand switch. IF
OK, SERVICE short
Key on, engine off. circuit. REMOVE
Measure voltage between Test Pin 43 (Test Pin breakout box.
24 for 2.3L OHC EFI) at the breakout box and RECONNECT all
chassis ground. components.
RE-EVALUATE
Is voltage less than 1.0 volt? symptom.

ALL RIGHTS RESERVED
Pinpoint
IOctane Adjust Test
KP
INote I
IRemember I
Harness circuits: VPWR, Octane Adjust
Octane shorting bar connector

SHORTING BAR
TO SIGNAL RETURN PIN

IN ECA
*TEST PIN 46 @-SIG RTN
TEST PIN 18 @ OCT ADJ -++-.......

(TEST PIN 44, 4.0L MA
TEST PIN 43, 1.9L MA SEFI)
OCTANE ADJUST
SHORTING BAR
VEHICLE HARNESS
CONNECTOR
10 OCTANE ADJUST
PIN IN ECA

ALL RIGHTS RESERVED
EECIV Pinpoint Test 'Proced~res 17329
Pinpoint
IOctane Adjust Test
KP
Octane Adjust Shorting Bar Locations

Application Location
Near EEC-IV power relay, fuel. pump relay and processor in
1.9L MA SEFI
passenger compartment.
2.3L EFI Truck
-
Passenger side of fender apron, taped to the Self-Test connector.
Driver side of engine, tie wrapped. to a bracket above the
3.0L SEFI SHO
transmission.
Passenger side of engine between shock tower mount and firewall
3.8L SEFI SC
next to Self-Test connector.
Driver side, engine cowl near windshield wiper motor take-out
4.0L MA EFI Aerostar
(alongside MAP take-out).
4.0L MA EFI Ranger/
Passenger side of fender apron, taped to the Self-Test connector.
Bronco II
Test Pin 18 Test Pin 46 SIG RTN

OCT ADJ
(44 and 43)
1.9L MA SEFI LG/BK
2.3L EFI Truck I
2.9L Scorpio BR
3.0L SEFI SHO BK/W
3.8L SEFI SC 4.9L F-Series/Bronco
4.0L Aerostar 0
4.0L Ranger W/R 7.5L F-Series
1.9L MA SEFI GR/W
All Others BK/W
The purpose of the Octane Adjust Shorting Bar is to produce effective combustion using
optimum spark advance.
If the vehicle detonates (spark knock), remove the Octane Adjust Shorting Bar. This will
retard spark an additional three .to four degrees.
If the vehicle continues to detonate (~park knock), use a higher octane grade of fuel.

ALL RIGHTS RESERVED
Intake Air Control Valve Pinpont

KT
(lAC) System Test
INote I
Quick Test or If you have been directed here from Diagnosis By Symptom.
IRemember I
may be at fault:
Vacuum tank leaks
Vacuum hose leaks

Harness circuits: VPWR and lAC
Intake Air Control Assembly (-9H465-)

*TEST PIN 37 a-- R - - - - VPWR INTAKE AIR CONTROL (lAC) SOLENOID
*TEST PIN 57 E>-- R VPWR
TEST PIN 32 &-- LG-P lAC ----~t:::!.J

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A12815B

ALL RIGHTS RESERVED

KT.
(lAC) System Test
KT1 ISERVICE CODE 81:

CHECK lAC SOLENOID RESISTANCE
Service Code 81 indicates that the Intake Air Yes ~ GO to IKT21.

Control (lAC) solenoid output voltage did not change
when activated during Key On Engine Off Self-Test. No ~ REPLACE lAC
Possible causes are: solenoid. RERUN Quick
Test.
- lAC circuit open
- lAC circuit short
- lAC solenoid disconnected
- Processor output driver open!grounded
Disconnect lAC solenoid.
Measure resistance between lAC circuit and
VPWR circuit at the lAC solenoid.
ohms?
I CJ I
lP?lJ:.
10 DVOM -----:::::::::~. ~
""'"nlA'f'l:: l
lAC SOLENOID ~ A12816-8
KT2 I CHECK VPWR CIRCUIT VOLTAGE
. Key on, engine off. Yes ~ GO to IKT31.

lAC solenoid disconnected.
DVOM on 20 volt scale. RECONNECT lAC
. Measure voltage between VPWR circuit of lAC Test.
solenoid vehicleharness connector and battery
negative pos~.
Is voltage greater than 10.5 Yolts?

ALL RIGHTS RESERVED

KT
(lAC) System Test
KT3 I CHECK lAC CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes ~ GO to IKT41.

for damaged pins, corrosion, loose wires etc. RECoNNECT all
Service as necessary. components. RERUN
Quick Test.
breakout box and lAC circuit at the lAC solenoid
KT41 CHECK lAC CIRCUIT FOR SHORT TO

GROUND
Key off, wait 10 seconds. Yes ~ GO to IKTSI.

F~ECONNECT all
Measure resistance between Test Pin 32 and Test Ouick Test.
KT5 I CHECK lAC CIRCUIT FOR SHORT TO POWER

lAC solenoid disconnected. RECONNECT all
Quick Test.
Pins 37 and 57 at the breakout box. REMOVE breakout box.
f~ECONNECT all
Is each resistance greater than 100,000 ohms? components. RERUN
Quick Test. If symptom
is still present,
REPLACE the
processor.

ALL RIGHTS RESERVED

.KT
(lAC) System Test
KT6 CHECK FRONT AND REAR INTAKE AIR

VALVES
Key off. Yes ~ GO to IKT71.

Disconnect vacuum lines from both intake air
valves. No ~ REPLACE intake air
valves as necessary.
Install vacuum pump at each intake air valve. REMOVE vacuum
pumps. RECONNECT
Apply 10 in-Hg vacuum to each of the intake air vacuum lines to both
valves. intake air valves.
RERUN Quick Test.
Did both intake air valves hold vacuum?
REAR INTAKE AIR VALVE
FRONT INTAKE AIR VALVE A12817-A
KT7 CHECK OPERATION OF BOTH INTAKE AIR

VALVES AND .LINKAGES
Key off. Yes ~ GO-to IKTsl.

Apply 10' in-Hg vacuum to both intake air valves.
Did both of the valves and valve mechanical RERUN Quick Test.
linkages move in response to the applied
vacuum?

ALL RIGHTS RESERVED

KT
(lAC) System Test
KT8 CHECK VACUUM TO BOTH INTAKE AIR

VALVES
Key off. Yes ~ GO to IKT91.

Check the vacuum lines from the front and rear
intake air valves to the lAC solenoid. Inspect for No ~ SERVICE vacuum lines
as necessary. RERUN
holes, kinks, disconnections and blockages. Quick Test.
Are vacuum lines OK?
REAR VACUUM LINE
lAC SOLENOID
VACUUM LINE
FRONT VACUUM LINE A12818B
KT9 CHECK SOURCE VACUUM TO lAC SOLENOID
Disconnect lAC solenoid manifold vacuum hose. Yes REPLACE lAC

Start engine. Test.
Check for vacuum at the disconnected manifold
vacuum hose. No ~ INSPECT vacuum
supply hose to lAC
Is vacuum present at the hose? solenoid. SERVICE as
necessary. RERUN
Quick Test:
lAC SOLENOID
MANIFOLD
VACUUM
HOSE

ALL RIGHTS RESERVED
Pinpont
IDynamic Response Test Test
M
INote I
Quick Test.
IRemember I
may be at fault:
Operator did not perform a brief WOT after Dynamic Response code.
Mechanical engine problems; engine did not achieve greater than 2000 rpm.
Throttle movement (greater than 3/4 throttle)
Vane Air Flow -meter (greater than 50 percent open)
Rpm increase (greater than 2000 rpm)

OPERATOR PERFO~MS BRIEF WOT RPM INCREASE
GREATEA THAN 2000 RPM
A9689-C

ALL RIGHTS RESERVED
I..
D_Y_D_a_m_iC_R_e_s_p_o_D_s_e_T_e_s_t 11 Pi;::nt II---_M_~
M1 ISERVICE CODE 77:

SYSTEM FAILED TO RECOGNIZE BRIEF WOT
NOTE: A brief snap of the throttle may not be Yes ~ REPLACE processor.
sufficient to pass this test. Be sure to go RERUN Quick Test.
to WOT and return.
Rerun Engine Running Self-Test. Be sure operator
No ~ Dynamic Response
Test passed. SERVICE
is familiar with the Engine Running format which any other service
proceeds as follows: code(s) received as
- Start engine. necessary.
- Activate Self-Test.
- ID Code 2 (0); start of test.
- Dynamic Response code 1 (0); perform brief
WOT.
- Testing over.
- Service code output begins.

ALL RIGHTS RESERVED
"CHECK ENGINE" or Pinpoint

"SERVICE ENGINE SOON" Light/Message' ML
"CHECK ENGINE"/"CHECKDCL'' ~essag~' . . Test
INote I
You should enter this Pinpoint Test only when a Service Code 70, 71, 72 is received
during Quick Test or when directed here from Pinpoint Test IQA I or Diagnosis By
Symptom.
IRemember I
may be' at fault:
Fuse, bulb or socket. ... r
STO/MIL circuit (All except 1.9L EFI)
MIL circuit (1.9L EFI only)
Processor assembly
Data Communications Link (DCl)

ALL RIGHTS RESERVED
"CHECK ENGINE" or
"SERVICE ENGINE SOON" Light/Message I Pinpoint I ML
"CHECK ENGINE"/"CHECK DCL" Message Test
--------
ALL EXCEPT 1.9L EFI
VBAT (DURING "RUN" OR "START")
SELF-TEST
"CHECK ENGINE" OR CONNECTOR
"SERVICE ENGINE SOON"
LIGHT
StOlMlL 12A581 HARNESS

*TEST PIN 17 .~-----------~----++I~I
*TEST PINS LOCATED ON BREAKOUT BOX

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE A992o-D
Test Pin 17 STO/MIL

Application Wire Colors
1.9L MA SEFI
3.8L RWD SEFI
Y/BK
3.8L SC SEFI
5.0L SEFI Mark VII
2.3L OHC EFI/MA
T
5.0L SEFI-MA Mustang
2.9L EFI Scorpio BR/GN
3.0L EFI Probe W/BL
F-Series/Bronco:
4.9L EFI, 5.0L EFI, 5.8L EFI PK/LG
7.5L EFI
7.3L Diesel F-Series
Afl Others T/R

ALL RIGHTS RESERVED
EEC'V Pinpoint Test Procedures 17339
"CHECK ENGINE" or Pi~point

"SERVICE ENGINE SOON" Light/Message
Test
ML
"CHECK ENGINE"/"CHECK DCL" Message

1.9L EFI
V8AT (DURING "RUN OR START")
"CHECK ENGINE" OR
"SERVICE ENGINE SOON"
LIGHT
*TEST PIN 53 .~T;..../R_M....;.IL_ 12A_5_8_1_HA_R.....

N,.;;.ES.-..,;S;..., ___
A 11541-C
All VEHICLES WITH DATA COMMUNICATION liNKS (Del)
SELF-TEST
CONNECTOR
*l~~T~IN 28 :
DATA (+)
TEST PIN 17 .l--------------

STO/MIL
DATA(-)
TEST PIN 8 AND 9 ~--------------'
*TEST PINS LOCATED ON BREAKOUT BOX

HARNESS CONNECTOR VIEWED INTO MATING SURFACE.
A 11607-C

ALL RIGHTS RESERVED

"SERVICE ENGINE SOON" light/Message ML
"CHECK ENGINE"/"CHECK DCl" Message Test
Test Pin 17 STO/MIL

1.9L MA SEFI Y/BK
2.3L OHC MA T
3.8L RWD SEFI Y/BK
All Others T/R
Test Pin 28/44 DATA(+)

1.9L MA SEFI Y/BL
2.3L OHC MA W/BK
3.0L EFI T/O
3.8L RWD SEFI SK/O
4.0L MA EFI, Aerostar
4.0L MA EFI, Ranger
T/R
All Others O/BK
Test Pin 8/9 DATA( -)

1.9L MA SEFI Y/BK
2.3L OHC MA W/P
3.0L EFI PK/LS
3.8L RWD SEFI O/SK
2.9L EFI MA, Truck
4.0L MA EFI, Ranger
T/O
All Others SK/O

ALL RIGHTS RESERVED

"SERVICE ENGINE SOON" light/Message ML
"CHECK ENGINE"/"CHECK DCl" Message Test
ML1 "CHECK ENGINE" OR "SERVICE ENGINE

SOON"
NOTE: If vehicle will not start go to Pinpoint Yes ~ SERVICE short circuit
Test SteP./A11. between Test Pin
17/53 and "CHECK-
If any Key On Engine Off service codes or ENGINE" or "SERVICE
Continuous Memory Codes are present, service ENGINE SOON" Light,
before proceeding. If no codes are outputted, or be'tween Test Pin
continue with this Test Step. 17 and the Self-Test
Connector. REMOVE
Key off. breakout box.
RECONNECT
Disconnect processor 60 pin connector. Inspect processor. RERUN
Install breakout box, leave processor disconnected. No ~ REPLACE processor.
..
53 on- 1.9L EFI) and Test Pin 40 at the breakout
box.
ML5 "CHECK ENGINE" OR "SERVICE ENGINE .

SOON" LIGHT NEVER ON:
CHECK CONTINUITY OF STO/MIL CIRCUIT
NOTE: If vehicle will not start go to Pinpoint Yes ~ GO to IML61.

Test Step IA11.
Refer to Quick Test Appendix for a J No ~ SERVICE OPEN circuit.
detailed description of how the "CHECK RECONNECT
ENGINE" or "SERVICE ENGINE SOON" processor. RERUN
light (malfunction indicator light) operates. Quick Test.
Key off.
wires, etc. Service as nec~ssa!y.
53 on 1.9L EFI) and the "CHECK ENGINE" or
"SERVICE ENGINE SOON" light.

ALL RIGHTS RESERVED

"SERVICE ENGINE SOON" Light/Message
Test
ML
"CHECK ENGINE"/"CHECK DCl" Message
ML61 CHECK FOR VOLTAGE TO BULB
Key off. .
Yes ~ GO to IML71.
No ~ GO to IMLSI.
Key on, engine off.
Measure voltage from battery negative post to the
"hot" side of the "CHECK ENGINE" I"SERVICE
ENGINE SOON" bulb.
ML7 I CHECK FOR FAULTY BULBISOCKET
Install known good bulbIsocket. Yes ~ RECONNECT

processor. BulbIsocket
Turn key to "RUN" position. was faulty.
Is "CHECK ENGINE" I"SERVICE ENGINE SOON"
light on? No ~ REPLACE processor.
VERIFY repair by
turning key to "RUN"
position.
MLSI CHECK FOR VOLTAGE AT FUSE
Key off. Yes ~ SERVICE fuse or open

in circuit. RECONNECT
DVOM on 20 volt scale. processor. VERIFY
Key on, engine off. repair by turning key to
"RUN" position.
Measure voltage from battery negative post to the
,,hot' , side of the fuse. No ~ SERVICE VBAT circuit.
Is the voltage greater than 10.5 volts? RECONNECT
processor. VERIFY
repair by turning key to
"RUN" position.

ALL RIGHTS RESERVED

"SERVICE ENGINE SOON" light/Message
Test
ML
"CHECK ENGINE"/"CHECK DCl" Message

SOON" LIGHT INTERMIITENTLY ON: CHECK
FOR INTERMIITENT STO SHORT TO GROUND
NOTE: If vehicle will not start go to Pinpoint' Yes ~ SERVICE short to

Test Step IA11. . round. RERUN Quick
est.
The "CHECK ENGINE" or "SERVICE
ENGINE SOON" light will come ON when
there is a Continuous Memory Code
No ~ UNABLE to duplicate
fault at this time.
present. Service any Continuous Memory Testing complete.
.Codes before proceeding.
(See Quick Test Appendix for description of
"CHECK ENGINE" or "SERVICE ENGINE SOON"
light function.)
If no codes are outputted, continue with this Test
Step.
Mode. Refer to Quick Test Appendix.
fault while you wiggle, shake or bend a small
section of the EEC-IV system harness. in the
following locations:
- Harness closest to Self-Test connector to the
dash panel
- Dash panel to the processor '.
- Dash panel to the "CHECK ENGINE" or

"SERVICE ENGINE SOON" light
"
. .,

ALL RIGHTS RESERVED

"SERVICE' ENGINE SOON" light/Message ML
"CHECK ENGINE"/"CHECK Del" Message Test

SOON" LIGHT FLASHING WITH ERRATIC
IDLE: CHECK FOR STI SHORT TO GROUND
NOTE: Vehicle symptoms indicate that STI is

grounded and the vehicle is actually
performing Self-Test without a tester
Yes . SERVICE short circuit.
RECONNECT
processor. VERIFY
installed. symptom eliminated.
Key off. No .~ RECONNECT

Disconnect processor 60 pin connector. Inspect processor. VERIFY
for damaged or pushed out pins, corrosion, loose symptom. REFER to
wires, etc. Service as necessary. Section 2 for rough
idle routines.
Measure resistance between the Self-Test Input
(STI) connector and engine block ground.
ML20 "CHECK ENGINE" MESSAGE DISPLAYED
NOTE: If vehicle is a no start, go to Pinpoint Yes ~ GO to Instrumentsl

Test Step IA11. Gauges Shop Manual
Group for DCl
Refer to Quick Test Appendix for detailed diagnosis.
description of how the "CHECK ENGINE"
message operates.
No ~ Self-Test indicates a
Run Key On Engine Off Self-Test. fault. GO to Quick
Test. Start with the
Is result 11-10-11 (Pass Codes)? first code displayed.
..

ALL RIGHTS RESERVED
"CHECK ENGINE'~ or Pinpoint

"SERVICE ENGINE SOON" Light/Message ML
"CHECK ENGINE"j"CHECK DCL" Message Test
..
Ml25 CONTINUOUS MEMORY CODE 70, 71, 72:

. "CHECK ENGINE" /"CHECK DCl" MESSAGE
DISPLAYED
Continuous Memory Codes 70, 71 and 72 indicate Yes ~ GO to Instrumentsl

that a circuit failure has occurred on the Data Gauges Shop Manual
Communications Link (DCl). These codes can Group for DCl
appear alone or in conjunction with one another. diagnosis.
The messages "CHECK ENGINE" and/or "CHECK
DCl" will also be on. No ~ Self-Test indicates a
fault. GO to Quick
- Code 70 indicates that the EEC IV processor is Test. Start with the
unable to transmit data. tir~t code displayed.
- Code 71 indicates that the Cluster Control

Assembly (CCA) is unable to transmit data.
- Code 72 indicates that the Message Center ,
Control Assembly (MCCA) is unable to transmit
data.
NOTE: If vehicle Is a no start, go to Pinpoint
Test Step IA11.
Refer to Quick Test Appendix for a "
detailed description of how the "CH.ECK
ENGINE"I"CHECK DCl" message .. '
operates.
I
Run Key On Engine 'Off Seit-Test with a STAR

tester or volt!ohmmeter.
Is result 11-10-11 (Pass Codes)?
-.
..
..

ALL RIGHTS RESERVED
Ignition/Erratic Pinpoint
N
Diagnostic Monitor (10M) Test
!Note I
48 or 88 is received during Quick Test, when directed here from Diagnosis By Symptom
or Section 13.
IRemember I
may be at fault:-
TFI, DIS or EDIS ignition module
'Ignition coil, DIS or EDIS coil packs
Spark plugs and high tension cables
Distributor and PIP sensor
Arcing of secondary ignition components
Harness circuits: IGN GND, SPOUT, PIP, 10M, DPI, SAW
Procesor assembly (-12A650-)
NOTE: This Pinpoint Test is intended to diagnose the EEC portion of TFI Ignition
Systems, Closed Bowl Distributor (CSD) with remote mount TFI Systems
Distrlbutorless Ignition Systems (DIS), and Electronic Distributorless Ignition
Systems (EDIS).
To identify your system, please refer to the application chart, below.
Ignition System Application Chart
Ignition Connector Vehicle Application

DIS Connector (pins 1-6 and 7-12) 2.3L Truck, 3.0L SHO, 3.8L SC
EDIS Connector (pins 1-12) 1.9L MA SEFI and 4.0L MA
Distributor Hall Connector and TFI Connector 3.8L RWD, 3.8L AXOD, 7.5L Truck
(used for Closed Bowl Distributor, Remote
Mount TFI Systems)
TFI Connector All Others

ALL RIGHTS RESERVED
N
Diagnostic Monitor (IDM) Test

TFI APPLICATIONS: 3.8L SEFI AXOD, 3.8L SEFI RWD, 7.5L EFI TRK
DISTRIBUTOR HALL VEHICLE

HARNESS CONNECTOR
TEST PIN 16 G ) - - - - - - - - - - I G N GND
TEST PIN 56 0---------- PIP - - - - -

IN-LINE,
SPOUT CONNECTOR
TEST PIN 36 0~-- Y/LG --~--SPOUT-----__i-+_----_+Hl
TEST PIN 4 0~-- DGN -----'\J\IVVV'vlDM --------t.----~-+HJ

22Kohms
TFI VEHICLE HARNESS
10 IGNITION CONNECTOR
COIL NEGATIVE
TERMINAL
A9251-B
Test Pin 16 - Ignition Ground Test Pin 36 Spout

Application Wir:e Color Application Location
3.8L SEFI AXOD GY F-Series Truck PK
.3.8L SEFI RWD All Others Y/LG
SKID
7.5L EFI TRK
Test Pin 56 PIP

TFI Location ... Application Location
Applicatio~ Location
F-Series Truck GY/O
3.8L SEFI AXOD Cowl
All Others OS
Radiator
3.8L SEFI RWD
Support
7.5L EFI TRK Distributor

ALL RIGHTS RESERVED
Ignition/Erratic Pinpoi..t
N

ALL OTHER TFI APPLICATIONS:
IN LINE SPOUT
CONNECTOR
"TEST PIN 56 <:> PIP'--------~---ttHt-;

TEST PIN 36 0 Y/LG SPOUT-------<. ....-~ofl
TO IGNITION
.... 22K OHMS COIL NEGATIVE
10M TERMINAL
_----------otJ
TFI TFI
VEHICLE MODULE
HARNESS CONNECTOR
TEST PINS LOCATED ON BREAKOUT BOX. CONNECTOR
.. NO 22K OHM RESISTOR FOR 2.3L MA, 3.0L CALIFORNIA CAR A9690-F
Test Pin 4 10M Test Pin Spout/SAW 36

3.0L Car (Calif. only) A/lB Application Wire Color
3.0l Probe GA 2.9L Car BLIR
3.0L SHO GY/O 3.0l Probe A
5.0L MA Lincoln Town 5.0l Lincoln Town Car GY/O
W/LB
Car
F-Series Trucks and
PK
F-Seriesl Bronco T/Y Bronco
All Others DG/Y All Others Y/LG
Test Pin 16 Ign. Gnd. Test Pin PIP 56

3.0L, 3.8l AXOD GY Application Wire Color
2.31L Truck, 2.9l Truck BK 2.9L Car Bl/Y
2.3L Merkur AIO 3.0l Probe . BK
Probe W F-Series Truck and
GY/O
Bronco
Scopio BA
All Others DB
All Others BK/O

ALL RIGHTS RESERVED
Ignition/Erratic . Pinpoint
N
1.9L MA SEFI (EDIS)

. VEHICLE HARNESS CONNECTOR
VRS(-)
(BL)
* TEST PIN 37 ~ .
TEST PIN 57 e-l---W/R--VPWR---I-I-I..........

I
-TEST PIN 16 0-- R/BL_IGN GND 1\

'- r--,~ ,I TO IGNITION
. I \ , I START/RUN
TEST PIN 36 0--LGIW.SAWG)E3'

. I
' R/Y
I t
I I
\ J COIL 1 _ ._ GR/Y j L
TEST PIN 56 0-- GR/W - PIP
COIL 2 _BRIR ~
TESTPIN4 0--R-IDM---+-- IGNITION COIL

VEHICLE HARNESS
CONNECTOR
~=;t:ES:ES:Ee=~~ BKIGR ~
BATTERY
G) SAW IN-LINE CONNECTOR - NEGATIVE
POST
EDiS MODULE
VEHICLE HARNESS, CONNECTOR
ALL HARNESS CONNECTORS VIEWED INTQ :MATING SURFACE.
A13559-A
..

ALL RIGHTS RESERVED
N
2.3 OHC EFI Truck (DIS)
DP1(32) GY10 --0 32 TEST PIN'

.!QM (4)jtUFF: TACH_ LG/N ~ 4 TEST PIN
VeAT: KEY POWER - - - - - - - - - - - - - -PIP (56) - - - - - - - - - - - - r, DB 056 TEST PIN
BOTH START & RUN DUAL HALL ,
SENSOR SP T (36)~_-..Jl- -+-_~\~Y~/L~G~0 36 TEST PIN
(SPK TIMING/CID) : IGN GND (16) I BKO 0 16 TEST PIN
I
LC~~~GND~20 TEST PIN
r-'--'-'----;---,
- - --
I
I
I
I
I
I
..c>"I'"'l'-~~III}
DIS
MODULE
(FRONT VIEW)
SECONDARY DIS PRIMARY DIS

SPOUT DISCONNECT COILS COILS
LOCATED ADJACENT TO THE LEFT SIDE RIGHT
Hi PIN DIS MODULE CONN. OF ENGINE V3AT sloe OF
1---------..... ---------------------------4~--.-.;..;;;....-....-.J ENGINE
A9252A
3.0L SHO SEFI MA and 3.8L SEFI SC (DIS)
,- - .)
CRANKSHAFT
SENSOR
(3.OL) SINGLE HALL ~-----:,-L='i-r-:.::-:.;::-::..::-=..:-=.;-==-=-:..:-=..:-=-:.::-::..::-=--=-:..;:-=--=..::-;....;-=r=-_......:~----~~-'0. 56 TEST PIN'
CRANKSHAFT (i> 24 TEST PIN
SENSOR 36 TEST PIN
PIP TO EEC 16 TEST PIN
4 TESTPIN
i
P;P ~ DIS VeAT : (i) 20 TEST PIN
KEY I IGNITION COIL
7 ~: ~
\ START ,
AND ' IGNITION COIL /h-r.....,r-n"
~T IGN GND RUN . (3.0l)
CRANKSHAFT
SENSOR
(3.8L)
~
~ __- -__= -__:_------------....:...;.:..:.::....:...:::------J >
A13537A
Test Pin 4 IDM Test Pin 16 Ign. Gnd.
1
1300L SHO MA GY/O f-~_O_L_S_H_O_M_A ~[---B-KL-8/-0---~
3.8L SC. MA DG/Y ,3.8L SC MA [

ALL RIGHTS RESERVED
N
4.0L MA EFI Truck (EDIS)

VRS(-) -, I '
, I
- - - - - - . + VBAT .
"TEST PIN 16
--------1
0-f-t IGN GND - BK/O I
+ VBAT
.I PIN 4
, \ I
TEST PIN 36 0 ,8 I SAW -Y/LG .I
, I I PIN 3
\ J I COIL 2 ---+--+++HJ1'r1
TEST PIN 56 0 \. J PIP I - + - - COIL 3-'-~H+f]UJ
----, II
-+-+-- COIL 1 PIN 2
I"" I
TEST PIN 4 0-IDM-DGIY I PIN 1
I
IGNITION COIL
I
VEHICLE HARNESS
I CONNECTOR
,..4.4-......- - - - . . ,
BATTERY
NEGATIVE
POST
EDIS MODULE
Test Pin 56 PIP

4.0L Aerostar DB

ALL RIGHTS RESERVED
Ignition/Erratic [ Pinpoint I N
Diagnostic Monitor .(IDM) Test L..- ...J
N1 ICONTINUOUS MEMORY CODE 14:

ERRATIC IGNITION
Code 14 indicates two successive erratic profile Yes ~ SERVICE as necessary.

ignition pickup (PIP) pulses occurred, resulting in a CLEAR Continuous
possible engine miss or stall. Memory Code 14.
Possible causes: Appendix.) RERUN
Quick Test.
- Loose wires/connectors.
- Arcing secondary ignition components (coil, cap, No ~ GO to lN41.
rotor, wires, plugs, etc.).
- On-board transmitter (2-way radio). *
Are any of the above present?
*Verify all 2-way radio installations. Carefully follow
manufacturer's installation instructions regarding the
routing of antenna and power leads.
N2 ISERVICE CODE 16: 10M CIRCUIT FAILURE

(EDIS)
Does engine start? Yes ~ GO to IN41.

No ~ GO to Section 13 for
EDIS Diagnosis.
N3 ICONTINOUS MEMORY CODE 18:

CHECK FOR OTHER EEC CODES
Code 18 indicates a loss of 10M Processor input. Yes ~ For DIS:

GO to IN131.
Possible causes:
- Open harness. For 4.0L EDIS:
GO to IN1SI.
- Shorted harness.
For 1.9L EDIS:
- DIS module. GO to IN171.
- Processor.
Are Continuous Memory Service Codes 45, 46
No ~ GO to \N41.
or 48 present?

ALL RIGHTS RESERVED
EECIV Pinpoint T~st Procedures 17353
N
TEST 'STEP RESULT ~ ACTION TO TAKE
N4 I CONTINUOUS MEMORY CODE 18, 28 OR 48:

CHECK CONTINUITY OF 10M CIRCUIT
"
Continuous Memory Code 18 indicates a loss of Yes ~ GO to INSI.

10M processor input.
Possible causes: No ~ SERVICE open circuit.
- Open harness. RECONNECT
processor. CLEAR
- Shorted harness. :
Continuous Memory
- TFI or DIS/EDIS module Codes. RERUN Quick
Test. RECONNECT
- Processor. Ecore ignition coil.
Continuous Memory Code 28 indicates 10M
processor input always low.
Possible causes:
- Open harness.
- Shorted harness.
~
- CID sensor.
- VBAT low at DIS.
- DIS module. ..
- Processor. '
"
I
Continuous Memory. Code 48 indicates 10M

processor input always high.
,
Possible causes: . '
- Open harness.
- VBAT open at secondary, coil.
- VBAT low at secondary coil.
NOTE: It is Important to know that on TFI
vehicles the IDM circuit has a 22,000 ~hm
resistor between Test Pin 4 and the
Ignition Coil Negative Terminal (except for
2.3L MA, 3.0L California cars).
'Key off, wait 10 seconds.
Disconnect E-core ignition c9i1 on TFI vehicles.
For DI.S vehicles: disconnect DIS module (pins
7-12).
For EDIS Vehicles:
. for damaged or pushed out pins, corrosion, loose
wires, etc. Service .as necessary.

ALL RIGHTS RESERVED
Ignition/Erratic
Diagnostic Monitor (10M)
I Pinpoint
Test
I N
L..- ~
N4 CONTINUOUS MEMORY CODE 18, 28 OR 48:

CHECK CONTINUITY OF 10M CIRCUIT
(Continued)
For TFI Vehicles:

breakout box and ignition coil harness connector
negative terminal.
For DIS/EDIS Vehicles:
breakout box and DIS module pin 12, EDIS
module 2 pin harness connector.
Is resistance between 20,000 and 24,000
ohms? (For DIS/EDIS and 2.3L MA, 3.0L
California cars is resistance less than 5.0
ohms?)
N5 CHECK 10M CIRCUIT FOR SHORT TO

GROUND
Key off, wait 10 seconds. Yes ~ GO to IN61.

E-core ignition coil disconnected on TFI vehicles.
For DIS vehicles: No ~ REMOVE breakout box.
DIS module pins 7-12 disconnected. SERVICE short to
For EDIS vehicles: ground in 10M circuit.
EDIS module disconnected. RECONNECT all
Breakout box installed, processor disconnected. components. CLEAR
DVOM on 200,000 ohm scale. Continuous Memory
Code. RERUN Quick
Measure resistance between Test Pin 4 and Test Test.
Is each resistance above 10,000 ohms?
N6 CHECK PROCESSOR FOR SHORT TO

GROUND
Key off. Yes ~ For TFI Vehicles:

Breakout box installed. RECONNECT E-Core
ignition coil.
For TFI Vehicles: For DIS Vehicles:
- E-core ignition coil disconnected. RECONNECT pins
For DIS Vehicles: 7-12.
- Disconnect Pins 7-12 at DIS connector. For EDIS vehicles:
For EDIS vehicles: RECONNECT EDIS
- EDIS module disconnected. module.
DVOM on 200,000 ohm scale. GO to IN71.
Pin 40, 46, and 60 at the breakout box.
RECONNECT all
components. RERUN
Quick Test.

ALL RIGHTS RESERVED
N
N7 I CHECK IGNITION MODULE
Key off, wait 10 seconds. Yes ~ GO to INSI.

Enter Engine Running Continuous Monitor Mode. No ~ DISCONNECT and
(Refer to Quick Test Appendix.) . INSPECT connectors. If
Observe VOM or STAR lED for indication of a connector and
fault while performing the following: terminals are good,
REMOVE breakout box,
Lightly tap on TFI or DIS/EDIS ignition (simulate RECONNECT all
road shock). components and GO to
Wiggle TFI, both DIS, or EDIS connectors. (For Section 13, IQnition
3.8l AXOD, 3.8l RWD and 7.5l truck, wiggle TFI Diagnosis. If Ignition
and distributor hall connectors.) .. system checks out OK
Is a fault indicated? in Section 13,
REPLACE processor.
N8 I CHECK EEC-IV HARNESS

While still in continuous monitor mode from Step Yes ~ ISOLATE fault and
I N71, observe VOM or STAR lED for a fault indication make necessary
while performing the following: repairs. REMOVE
While looking for faults listed in the table below, breakout box.
~ra~ the harness close to the TFI, both DIS, or DISCONNECT all
01 connectors. (For 3.8l AXOD, 3.8l RWD and components. CLEAR
7.5L Truck, TFI and distributor hall connectors.) Continuous Memory
Wiggle, shake or bend a small section of the Code. RERUN Quick
EEC~IV system harness while working your way to. Test.
the other ignition system components and to the
dash panel. Also wiggle, shake or bend the EEC- No ~ GO to IN91.
IV harness from the dash panel to the processor.
Do this test on the circuits listed one at a time if
needed to locate a faulty circuit.
FAULT BREAKOUT
BOX NO.
PIP shorted to ground or open Test Pin 56
Spout shorted to ground Test Pin 36
Ign. ground open Test Pin 16
10M open or shorted to ground,
Test Pin 4
power

ALL RIGHTS RESERVED
Ignition/Erratic I Pinpoint I N
Diagnostic Monitor (10M) Test L-- --'
N9 I
CHECK PROCESSOR AND HARNESS
CONNECTORS
Key off, wait 10 seconds. Yes ~ For Continuous

Disconnect processor 60 pin connector. Inspect Memory Code 14:
for damaged or pushed out pins, corrosion, loose Unable to duplicate an
wires, etc. erratic ignition fault in
the EEC-IV system.
Are connectors and terminals OK? REMOVE breakout box.
RECONNECT all
components. For
further diagnosis, GO
to Section 13, DIS
- . Diagnosis.
For Continuous
Memory Code 18:
REPLACE processor.
RECONNECT all
components. Start
engine and run for
about one minute.
RERUN Quick Test.
For Continuous
Memory Codes 28
and 48:
RECONNECT all
Section 13, DIS
Diagnosis. If ignition
system checks out OK
in Section 13,
REPLACE processor.
RECONNECT all
components. CLEAR
Continuous Memory
Codes. (REFER to
Quick Test appendix.)
RERUN Quick Test.

ALL RIGHTS RESERVED
N
TEST STEP RESULT' ~ ACTION TO TAKE

CHECK CAMSHAFT SENSOR OUTPUT
Service Code 19 indicates, that one of the two Yes ~ REPLACE processor.
cylinder identification (CID) sensor output signals has REMOVE breakout box.
failed. One of the outputs is input to the RECONNECT all
components~ RERUN
Distributorless Ignition System (DIS). The second
Quick Test.
output is input to the EEC-IV processor. Each output
has a 50 percent duty cycle and an amplitude that
varies from 0.4 volts to VBAT. No ~ GO to [HIT] .
Possible causes:
- CID output line to processor open.
- CID output line to procesor shorted to ground.
- CID output line to processor shorted to power.
Key off.
Disconnect processor 60 pin connector, inspect
wires, etc.
breakout box.
Key on engine running.
pVOM on AC scale.
Measure voltage between Test Pin 24 and
GROUND.
Does voltage vary?

ALL RIGHTS RESERVED
. Test N
Diagnostic Monitor (10M)
N11 I CHECK CID HARNESS FOR CONTINUITY
Key off. Yes ~ GO to IN12\.

RECONNECT all
Disconnect distributorless ignition module. components. RERUN
breakout box and pin 2 (CID) at the DIS module
connector.
N12 I CHECK CID CIRCUIT FOR SHORTS

RECONNECT all
Breakout box installed, processor disconnected. components. GO to
DIS module disconnected. Section 13, TFI or DIS
diagnosis.
Measure resistance between Test Pin 24 and Test No ~ SERVICE CID circuit
Pin 16, 37. 40 at the breakout box. tor short to GROUND
or POWER. REMOVE
Is each resistance greater than 10,000 ohms? breakout box.
RECONNECT all
components. RERUN
Quick Test.

ALL RIGHTS RESERVED
N
N13 CONTINUOUS MEMORY CODES 45, 46 OR 48:

CHECK CONTINUITY OF COIL CIRCUITS FROM
~
DIS TO COIL PACK
Service Codes 45, 46 and 48 indicate a fault has Yes ~ GO to IN141.

been detected by the processor in one of the three
coils contained in the ignition coil pack. No ~ SERVICE open circuit.
RECONNECT all
.NOTE: Codes 45, 46 and 48 refer to faults components. RERUN
detected in the circuits related to coils 3, Quick Test.
1 or 2 respectively. Coil 1 provides
voltage for cylinder three and four spark
plugs. Coil 2 provides voltage for cylinder
two and six spark plugs. Coil 3 provides
voltage for cylinder one and five spark
plugs.
The 10M pulse train contains a
corresponding pulse for each operating
coil. In the event that a coil fails, the
corresponding pulse will be absent from
the 10M pulse train.
Possible causes:
- Open in coil circuit from DIS module to coil
pack.
- Shorts to coil circuit GND or PWR in DIS
module.
Disconnect DIS module.
Measure resistance between pin 8 at the DIS
module and coil 1 at the ignition coil pack.

ALL RIGHTS RESERVED
17360 EEc.lV Pinpoint Test Procedures
N
N141 CHECK COIL PACK CIRCUIT FOR SHORTS TO

GROUND AND POWER .
Key off. Yes ~ REFER to Section 13

for DIS Diagnosis.
DIS module disconnected pins 7-12.
Disconnect coil pack. No ~ SERVICE short circuit.
RECONNECT all
DVOM on 200;000 ohm scale. components. RERUN
Measure resistance between pin 7 and pins 8, 9 Quick Test.
and 11 at the DIS module connector.
Measure resistance between pin 1 and pins 8, 9
and 11 at the DIS module connector.

ALL RIGHTS RESERVED
N
N15 CONTINUOUS MEMORY CODES 45:

CHECK CONTINUITY OF COIL CIRCUITS FROM
EDIS TO COIL PACK
Service Code 45 indicates a fault has been Yes ~ GO to IN161.

detected by the processor in one of the three coils
contained in the ignition coil pack. No ~ SERVICE open circuit.
RECONNECT all
NOTE: 'Codes 45 refer to faults detected in the
components. RERUN
circuits related to coils 3, 1 or 2 Quick Test.
respectively. Coil 1 provides voltage for
cylinder three and four spark plugs. Coil
2 provides voltage for cylinder two and
six spark plugs. Coil 3 provides voltage
for cylinder one and five spark plugs.
The 10M pulse train contains a
corresponding pulse for each operating
coil. In the event that a coil fails, the
corresponding pulse will be absent from
the 10M pulse train.
Possible causes:
- Open in coil circuit from EDIS module to coil
pack.
- Shorts to coil circuit GND or PWR in EDIS
module.
Disconnect DIS module.
Measure resistance between pin 10 at the ED'S
module and the coil 1 pin at the ignition coil
pack.
Measure resistance between pin 11 at the EDIS
pack.
Measure resistance between pin 12 at the ED'S
pack.

ALL RIGHTS RESERVED
17362 EECIV Pinpoint' Test Procedures
Ignition/Erratic I Pinpoint I N
'--------'
N16 CHECK COIL PACK CIRCUIT FOR SHORTS TO

GROUND AND POWER

EDIS module disconnected pins 1-12. for EDIS Diagnosis.
Disconnect coil pack.
RECONNECT all
Measure resistance between pin 4 and pins 10, components. RERUN
11 and 12 at the EDIS module connector. Quick Test.
Measure resistance between pin 8 and pins 10,
11 and 12 at the EDIS module connector.
N17 CONTINUOUS MEMORY CODE 45/46:

CHECK CONTINUITY OF COIL CIRCUIT FROM
EDIS TO COIL PACK
Service codes 45 (coil 1) and 46 (coil 2) indicate a Yes ~ GO to IN1SI.

primary circuit fault has been detected by the
processor in the corresponding ignition coil pack.
4 Cylinder EDIS RECONNECT all
components. RERUN
Plug Firing Order 1 3 4 2 Quick Test.
Coil Pack Number 1 2 1 2

- Open or short in coil circuit between the EDIS
module and the coil pack.
- Faulty coil.
- Faulty EDIS.
Key off.
Disconnect coil pack.
Measure resistance between pin 10 (coil 1) at the
EDIS module vehicle harness connector and coil 1
pin at the coil pack vehicle harness connector.
Measure resistance between pin 12 (coil 2) at the
EDIS module vehicle harness connector and Coil
2 pin at the coil pack vehicle harness connector.

ALL RIGHTS RESERVED
N
N181 CHECK COIL CIRCUIT FOR SHORT TO

GROUND AND POWER

for EDIS diagnosis.
EDIS module disconnected.
Coil pack disconnected. No ~ SERVICE short circuit.
RECONNECT all
Measure resistance between pin 9 (SAn GND) Quick Test.
and pins 10 (Coil 1) and 12 (Coil 2) at the EDIS
Measure resistance between pin 8 (VPWR) and
pins 10 and 12 at the EDIS module vehicle
harness connector.

CHECK CONTINUITY OF DPI CIRCUIT
Continuous Memory Code 88 indicates an open in Yes ~ REMOVE breakout box.

the dual plug inhibit (DPI) circuit or an open or RECONNECT all
short to ground in coil 4.
, components. REFER to
Section 13, DIS
Possible causes: Diagnosis. If ignition
system checks OK in
- Open in harness. Section 13, REPLACE
- Short in harness. processor.
- Processor.
- DIS module. REMOVE breakout box.
RECONNECT all
- Coil 4 failure. components. RERUN
. Quick Test.
Disconnect DIS connector (pins 1-6)

Disconenct Processor 60 pin connector. Inspect
wires, etc. Service as nec_essary.
vehicle harness connector and Test Pin 32 at the
breakout box.

ALL RIGHTS RESERVED
N
N25 HARD TO START:

CHECK DPI CIRCUIT FOR SHORT TO
GROUND
Key off, wait 10 seconds. Yes ~ Go to IN261.

Disconnect DIS connector (pins 7-12).
Quick Test.
Insall breakout box, leave processor disconnected.
N26 CHECK PROCESSOR FOR SHORT TO

GROUND

RECONNECT all
DIS connector (pins 7-12) disconnected. components. GO to
Breakout box installed. Section 13, DIS
Diagnosis.
DVOM on 200,000 ohm scale. No ~ REPLACE processor.
Pins 40 and 60 at the breakout box. components. RERUN
Quick Test.
Is resistance greater than 500 ohms?

ALL RIGHTS RESERVED
Pinpo~nt
ISpark Timing Check Test
p
INote I
You should enter this Pinpoint Test only when checking computed timing, a Service
Code 18 or 49 Is received during Quick Test. .
IRemember I
may be at fault:
Base Engine Camshaft Sensor (CID)

Distributor Single Hall Crankshaft Sensor (PIP)
TFI, DIS or EDIS Module Dual Hall Sensor
Harness circuits: SPOUT and SAW
Base Timing

ALL TFI APPLICATIONS
-TEST PIN 36 G).......-._Y_/L_G_ _ <<E SPOUT - - - l t - I i - - U

1N-lINE
SPOUT CONNECTOR
TFI TFI
VEHICLE MODULE
HARNESS CONNECTOR
CONNECTOR

ALL RIGHTS RESERVED
Pinpoint
[Spark Timing Check P
Test
2.3L OHC EFI Truck
VBAT: KEY POWER r- D_P.....;I(_32..;..)_ _ ;no~'""'...,............,......--GMLGcr~/fY0n--0 32 TEST PIN"

BOTH START & RUN luM 4) BUFF. TAC.!.l.H'-----=::~_0 4 TEST PIN
DUAL HALL - - - - - - - - - - - - - - - - pip {56) - - - - - - - - -- r, DB 0 56 TEST PIN
SENSOR
(SPARK TIMING/CtD)
,..,I~ SPOUT (36)_1'1'- ...-+~..,:,Y:.::/L~G'--0 36 TEST PIN 1
..-- IGNGND(16) I I BKO 0 16TESTPIN
- - -- t~~E~ND~ 20 TEST PIN
o
SHIELD DIS
CONNECTOR MOOULE
(FRONT VIEW)
PRIMARY DIS
COILS
RIGHT
SIDE OF
L....4_~E=..:,NGINE
SECONDARY DIS
COILS
SPOUT DISCONNECT
LEFT SIDE
LOCATED ADJACENT TO THE
L: _ OF ENGINE
16 PIN DIS. MODULE CONNECTOR VBAT A9255A
3.0L SHO SEFI MA and 3.8L SEFI SC
CRANKSHAFT
SENSOR
(3.0l) ....----...L.::;:.=-=:..=..;::.=..=-=:...=..;=:.=..:=-=-.=..:=-=-=-=:;.::~:!f::.-------JPG~--0 56 TEST PIN"
"----+';.,,:.;..,....:,;:;.,:;;:.>o.,;.;-...-_-_-=--_-_-_-=--=--=--_-.....:t-_-....,l;--1'~~'~~:-=_---=------=-------',Y~/~l~G;:--<!)~
~ f~~ ~l~
~_:L~~~-+'M~_=_=____.~__=_=:-:-' ..........~~!!!!:!-----_0 16 TEST PIN
r---~::__:_::-:=----=-0 4 TEST PIN
" - - - / f ' - - ~~!.!L- ~BK~_0 20 TEST PIN
IGNITION COIL
(3.8L)
IGNITION COIL r,...-::===:".,

(3.0l)
CRANKSHAFT
SENSOR
(3.8l)
1 12
, 2 11
DIS
~D MODULE
(lOP VIEW)
0 10
9
POU 5 8
INL1NE 6 7
SPOUT
DIS MODULE CONNECTOR
PINS 1-6 PINS 7-12
"TEST PINS LOCATED ON BREAKOUT BOX. ALL HARNESS CONNECTORS VIEWED INTO
MATING SURFACE. A13537-A
3.8L SC MA
Test Pin 4
1300L SHO MA
10M
GY/O
DG/Y
3 .OL SHO MA
~--- '--LS--
3.8L SC MA
1
_
Test Pin 16
SK/O t Ign Gnd

ALL RIGHTS RESERVED
Pinpoint
P
1.9L MA SEFI

VRS (-)
(BL)
TEST PIN 37 e--, .

TEST PIN 57 ~W/R--VPWR---1'-+-"""'_
I
TEST PIN 16 0-- R/BL-IGN GNO 1\

-Q " TO IGNITION
,
I \ r START/RUN
TEST PIN 36 &-LG/W-SAW<D[}

. I
I
I R/Y
J
,
t
d!J
COIL 1 _ _ GR/Y - t i J j L
I I
TEST PIN 56 0--GR/W - PIP-~""""
COIL 2 - BR/R
TEST PIN 4 <:r--- R-IOM - - - +... IGNITION COIL

VEHICLE HARNESS
CONNECTOR
&=::::t:~::t::;t::t:::t::::t=t=I:=t:~t==,- BKlGR ~
BATTERY
CD SAW IN-LINE CONNECTOR NEGATIVE
POST
EDIS MODULE
A13559A

ALL RIGHTS RESERVED
Pinpoint
'p
4.0L MA EFI Truck

YVRS(+)
VRS (-) ,... VRS SHIELD
, . . - - - - -.. + VBAT
--------11 + VBAT
L~,
"TEST PIN 16 0--(-TIGN GND- BKiO
PIN 4
\ I
TEST PIN 36 <:> '0 I SAW -Y/LG :
I , PIN 3
\ I COIL 2 ---I--t+I+oOn""
<:> \.}
TEST PIN 56
----,PIP
I ..
. - + - - COIL
~.......-COIL
3---"...u+W1
1---111.......~J1 PIN 2
TEST PIN 4 0-IDM-DG/Y
PIN 1
IGNITION COIL
VEHICLE HARNESS
CONNECTOR
BATTERY
NEGATIVE
POST
EDIS MODULE VEHICLE
HARNESS CONNECTOR
ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A13560A
Test Pin 56 PIP

4.0L Aerostar DB

ALL RIGHTS RESERVED
Pinpoint
P
P1 IENGINE RUNNING SERVICE /CODE 18:

CHECK COMPUTED SPARK TIMING
For TFI Vehicles: Yes ~ GO to Quick Test Step

15.01.
Engine Running Service Code 18 indicates that the
SPOUT circuit is open.
No . ~ GO to Ip21 .
Possible causes:
- Open harness.
- Processor.
- TFI module.
For DIS Vehicles:
Engine Running Service Code 18 indicates that lthe
SPOUT circuit is either open or shorted to ground.
Possible causes:
- Processor. ..
- DIS module.
For EDIS Vehicles:
Engine Running Service Code 18 indicates that .the
SAW circuit is either open or shorted to ground!
VBAT.
Possible causes:
.
- Processor.
- EDIS module.
NOTE: Self-Test locks the computed timing at
base timing plus 20 degrees (3 degrees)
during code output and for two minutes
after the last service code is outputted.
"fiming check must be made during this
time period. See VEeI decal for base
timing value.
Check timing (on 2.3L DIS truck, use exhaust side
plug). Record value.
Is computed timing equal to base timing plus
20 degrees ( 3 degrees)

ALL RIGHTS RESERVED
Il.-s_p_a_r_k_T_i_m_i_D_9_C_h_eC_k 11 Pi;:::ntI~_p_------I
P2 I CHECK BASE SPARK TIMING
Key off. Yes ~ RECONNECT SPOUT

connector. GO to IP3! .
Locate in-line SPOUT/SAW connector and open
this connection.
No ~ For TFI:
Start engine. Adjust base timing if
necessary. REFER to
Check base timing. Section 13 for engine
Is base timing within 3 degrees of value on timing instructions. After
VECI decal? timing is reset,
RECONNECT in-line
SPOUT connector and
GO to Quick Test Step
14.01.
For DIS and EDIS:
Base timing is not
adjustable. GO to
Section 13 or Ignition
System Diagnosis.
P3 I CHECK FOR POWER TO PROCESSOR
Key off, wait 10 seconds. Yes ~ GO to Ip41.

for damaged or pushed out pins, corrosion, loose No ~ For 2.5L HSC CFI,
wires. Service as necessary. 3.0L SHO, 3.0L EFI,
3.8L SC, and 3.8L
Install breakout box, leave processor disconnected. . AXOD EFI passenger
cars:
Key on, engine off. GO to Pinpoint Test
DVOM on 20 volt scale. Step [!I] .
,
Measure voltage between Test Pin 37 and Test For all others:
Pin 40 at the breakout box. GO to Pinpoint Test
Step OOJ.
Measure voltage between Test Pin 57 and Test.
Pin 60 at the breakout box. .

ALL RIGHTS RESERVED
ISpark Timing Chec~ Pinpoint

Test
P
P4 CHECK SPOUT/SAW CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes ~ For DIS/EDIS

vehicles:
Breakout box installed, processor disconnected. GO to Ipsl.
Disconnect DIS module (Pins 1-6), TFI module, or
For TFI vehicles:
EDIS module.
GO to Ip61.
breakout box and SPOUT/SAW circuit at the DIS, REMOVE breakout box.
RECONNECT all
TFI or EDIS module vehicle harness connector.
components. CHECK
Is resistance. less than 5 ohms? timing per IP11 .
TFI MODULE VEHICLE

HARNESS CONNECTOR
TEST PIN 36 .>-H-+-_ _S;;.,,;,P....;O....;U;..;.T~...[]
IN LINE
SPOUT
CONNECTOR
A9990-D
DIS MODULE
VEHICLE HARNESS
CONNECTOR
(PINS 1-6)
TEST PIN 56 0- PIP ------~I+f+I"1
TEST PIN 36 0- SPOUT
A9257-B
EDIS MODULE
VEHICLE
HARNESS
CONNECTOR
TEST PIN 360-- SAW

TEST PIN 560-- PIP---------II-IoOUi

ALL RIGHTS RESERVED
17-372 . EEC-IV Pinpoint Test Procedures
l_s_p_a_r_k_T_im_iD_g_C_h_e_C_k II. Pi;:::nt I'---_p_---'

P5 I CHECK SPOUT/SAW CIRCUIT FOR SHORTS

TO POWER, GROUND AND PIP
Key off, wait 10 seconds. Yes ~ GO to Ip61.

DIS module (pins 1-6) or EDIS module REMOVE breakout box.
disconnected. RECONNECT all
components. RERUN
For Shorts To Ground:
Test Pins 16, 20, 40, 46 & 60.
For Shorts To Power:
Test Pins 26, 37 & 57.
For Short To PIP Circuit:
- Measure resistance between Test Pin -36 and
Test Pin 56.
P6 I CHECK SPOUT VOLTAGE AT PROCESSOR
Key off, ,wait 10 seconds. Yes ~ EEC system OK.

Breakout box installed. RECONNECT
Connect processor to breakout box. processor. GO to
Section 13 for Ignition
Reconnect TFI, DIS or EDIS module. System Diagnosis.
Timing switch to "DIST" position on breakout box.
DVOM on 20 volt. scale. REMOVE breakout box.
Measure voltage between Test Pin 36 at the RERUN Quick Test.
breakout box and battery negative post during
Engine Running Self-Test.
For EDIS vehicles:
For all others:

ALL RIGHTS RESERVED
ISpark Timing Check Pinpoint

Test
P
P10 ICONTINUOUS MEMORY CODE

CHECK SPOUT CIRCUIT CONTINUITY
49:
Service Code 49 indicates the spark timing has Yes ~ GO to IP111 .

defaulted to 10 degrees BTDC. The SPOUT signal
has a variable duty cycle with amplitude that varies
from 0.4 volts to VBAT. In the event of a SPOUT
No ~ VERIFY in-line SPOUT
connector is properly
failure, the DIS module will generate a fixed dwell
connected. If OK,
and constant spark angle based on 91D and PIP
SERVICE open circu!t.
signals (FMEM mode).
RECONNECT all .
Possible - causes: components. RERUN
Quick Test.
- Faulty DIS module
- Faulty SPOUT circuit. ...
wires, etc. Service as ~ecessary.
Breakout box installed, leave processor
disconnected.
Disconnect DIS module (pins 1-6).
-
breakout box and SPOUT circuit at the DIS
P11 I CHECK SPOUT CIRCUIT FOR SHORT TO

POWER AND GROUND
Key off, wait 10 seconds. Yes ~ EEC system OK.

DIS module disconnected. RECONNECT all
Breakout box installed, processor disconnected. components. GO to
Section 13 for TFI or
DIS diagnosis.
Measure resistance between Test Pin 36 and Test .
No ~ SERVICE SPOUT
Measure resistance between Test .pin 36 at the circuit for short to
breakout box and battery positive post. POWER, or GROUND.
Is each reistance greater than 10,000 ohms?
RECONNECT all
components. RERUN
Quick Test.

ALL RIGHTS RESERVED
No Codes/Codes Not I Pinpoint I QA

Listed Test L-- ~
INote I
You should enter this Pinpoint Test only when you have been directed here from Quick
Test.
IRemember I
Processor (-12A650-) Harness Circuits: SIG RTN, STO, STI,

VPWR, VREF, PWR GND
EEC Power Relay (-12A646-)
IPinpoint Test Schem~ticI

TEST PIN 46 @ SIG. R T N . - - - - - - - - -___
"CHECK ENGINE" OR "SERVICE ENGINE SOON" LIGHT
VBAT ~ MIUSIL PIGTAIL
MIL EQUIPPED VEHICLES ~ CONNECTOR
TEST PIN 17 @ - - - - S T O - - - - - - + - - - - . . . . . . J c : : : : J TO
SELF-TEST
T~ST PIN 4 8 @ - - - - S T I - - - - - - - - - - - - - - - I N P U T
TEST PIN 40 G)----PWR GND ----------~--< -~ ~~n

TEST PIN 60 @ PWR GND GND
PIGTAIL
TO .....,.---IGNITION----~~_+U a EEC POWER RELAY

IGN. SW. VEHICLE HARNESS
CONNECTOR
r-mMTIE~
TEST PIN 37 @ _ - - - V P W R - - -..
TEST PIN 57 @-------VPWR-----J
TO
KAM
TEST PIN 49 @ O " " - " - - - E G O G N D . - - - - - - - - - - - - - - < : )

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A9692-F

ALL RIGHTS RESERVED
.EEC~IV Pinpoint Test Procedures 17-375
No Codes/Codes Not Pinpoint

QA
Listed Test
SelfTest Output and Test Pin 40/60 PWR GND

"Check Engine" or
.- Application Wire Color
"Service Engine Soon"
Test Pin 17 Light 1.9L MA SEFI BK/GR
Application Wire Color 2.9L Scorpio BR
2.9L Scorpio BR/GN 4.9L F-Series/Bronco
3.0L Probe W/BL
5.8L F-Series/Bronco BK/W
5.0L SEFI Mark VII 7.5L F-Series
3.8L RWD SEFI Y/BK 7.3L Diesel
3.8L SC SEFI
. 3.0L Probe*
1.9L MA SEFI
All Others BK/LG
5.0L SEFI MA Mustang
T * Except 3.0L Probe test
2.3L OHC EFI BK/Y
pin 60
1.9L EFI T/LB
Test Pin 49 EGO GND
4.9L EFI F-Series/Bronco
5.0L EFI F-Series/Bronco Application Wire Color
5.8L EFI F-Series/Bronco PK/LG
1.9L MA SEFI BK
7.3L Diesel
7.5L F-Series/Bronco 2.9L Scorpio BR
All Others T/R 5.0L MA Lincoln Town
Car GY/LB
Test Pin 48 SelfTest Input
3.0L Probe BK/LG
All Others 0
2.9L Scorpio BL/GN
Test Pin 46 SIG RTN
5.0L MA Mustang T/R
1.9L MA SEFI LG/Y
1.9 MA SEFI LG/B
5.0L F-Series/Bronco 2.9L Scorpio BR
5.8L F-Series/Bronco W/P
7.5L F-Series
7.3L Diesel
3.0L EFI Taurus/Sable 7.5L F-Series
3.8L EFt AXOD 7.3L F-Series Diesel
2.5L CFI FLC
3.0L Probe LG/Y
2.5L CFI MTX W/BK
5.0L SEFI Crown All Others BK/W
Victoria/Grand Marquis
All Others W/R
Test Pin 37/57 VPWR

1.9L MA SEFI W/R
2.9L Scorpio BK
3.0L Probe R/BK
All Others R

ALL RIGHTS RESERVED
No Codes/Codes Not I Pinpoint I QA

Listed Test
'-------~
QA1 ICHECK VREF VOLTAGE AT SELF-TEST

CONNECTOR
Key off, wait 10 seconds. Yes ~ GO to IQA21.

for damaged or pushed out pins, corrosion, loose No ~ GO to Pinpoint Test
wires, etc. Service as necessary. Step ~.

breakout box.
Key on, engine off.
breakout box and SIG RTN in the Self-Test
connector.
QA2 I CHECK STI CIRCUIT CONTINUITY
Key off, wait 10 seconds. Yes ~ GO to IQA31.

RECONNECT
processor. RERUN
Measure resistance between STI in the Self-Test Quick Test.
single pin pigtail connector and Test Pin 48 at the
breakout box.
Is resistance less than S ohms?
QA3 I CHECK STO CIRCUIT CONTINUITY
Key off. Yes ~ For 1.9L vehicles:

GO to IQA41.
DVOM on 200 ohm scale. For all others:
GO to IQASI.
Measure resistance between STO in the Self-Test
connector and Test Pin 17 at the breakout box. No ~ SERVICE open circuit.
Is resistance less than 5 ohms? REMOVE breakout box.
RECONNECT
processor. RERUN
Quick Test.

ALL RIGHTS RESERVED

QA
Listed Test
QA4 I CHECK EGO GND CIRCUIT CONTINUITY
Key off. Yes ~ GO to IQASI.

Breakout box installed, ,processor disconnected.
RECONNECT
'. Measure resistance between EGO GND at the processor.. RERUN
engine and Test Pin 49 at the breakout box. Quick Test.
QA51 CHECK STO CIRCUIT FOR SHORT TO

GROUND
Key off. Yes ~ SERVICE STO or MILl

SIL circuit for short to
breakout box.
RECONNECT
Measure resistance between STO in the Self~Test processor. RERUN
connector and engine block ground. Quick Test.
No ~ ~O to IQA61.
QA6 I CHECK IF POWER RELAY IS ALWAYS ON
Key off. Yes ~ For vehicles equipped

with MIL (malfunction
Breakout box installed, processor disconnected. indicator light
Connect DVOM to Test Pin 37 or 57 and. to Test displayed as
Pin 40 or 60 at the breakout box. "CHECK ENGINE" or
"SERVICE ENGINE
DVOM on 20 volt scale. SOON" light) or SIL
(shift indicator light):
Turn key on and then off. Wait 10 seconds. GO to IQASI.
Does voltage change from greater than 10.5
volts to zero volts? For all others:
REPLACE the
processor. REMOVE
breakout box. RERUN
Quick Test.
No ~ GO to IQA71.

ALL RIGHTS RESERVED

QA
Listed Test
QA71 CHECK VPWR CIRCUIT FOR SHORT TO

POWER
Key off. Yes ~ SERVICE VPWR circuit

short to power.
RECONNECT all
EEC Power Relay or Integrated Relay Controller
components. RERUN
disconnected.
. Quick Test.
Measure voltage between Test Pin 37 or 57 and No ~ REPLACE EEC Power
Test Pin 40 or 60. at the breakout box. Relay or Integrated
Relay Controller.
Is voltage greater than 10.S volts? REMOVE breakout box.
RECONNECT
processor. RERUN
Quick Test.
QAS I MIL AND/OR SIL EQUIPPED VEHICLES

Are any of these conditions present?
Shift indicator light:
....
- Always ON JlI""" GO to IKL11.
- Always OFF ~ GO to IKL11.
Malfunction indicator light:

- Always ON ~ GO to IML11.
- Always OFF ~ GO to IMLSI.
Shift and malfunction indicator lights functioning ~ REPLACE the processor.

normally RERUN Quick Test.

ALL RIGHTS RESERVED
Key On Engine Off and/or Pinpoint

Continuous Memory QB
Service Code 15. Test
INote I
You should enter this Pinpoint Test only when you ha.ve been directed here from Quick
Test.
IRemember I
. .
Harness circuits: PWR GND, VPWR, KAPWR, IGNITION

*TEST PIN 40 G)~-PWR GND---------------.---<.-e
TEST PIN 60 0 ,PWR G N D - - - - - - - - - - - - - -.... TO
BAn
GND
PIGTAIL
TGO
IN. SW. ~ IGNITION - - - - - - ( t-"----f-ll
TEST PIN 37 0--- VPWA - - - - -

TEST PIN 57 0--- VPWR ----~ r---~ 10 BAnERY
TO
STARTER
TEST PIN 1 00......-- KAPWR --------.-.--40-f MOTOR
FUSE RELAY
LINK
-TEST PINS LOCATED ON BREAKOUT BOX

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE
A11503-C

ALL RIGHTS RESERVED

Continuous Memory . QB
Service Code 15 Test
Test Pin 1 KAPWR

2.3L OHC, MA/NON-MA
5.0L SEFI MARK VII
5.0L SEFI-MA
5.0L EFI, E-Series
BK/O
7.5L E-Series
7.3L E-Series/Diesel
5.8L E-Series
4.9l E-Series
4.9L Ranger MA/NON-MA
Y/BK
5.0L Lincoln Town Car
2.3L Ranger/Supercab
1.9L MA SEFI
BUR
3.0L Probe
2.9L Scorpio BK/BL
All Others Y
Test Pin 40/60 PWR GND

1.9L MA SEFI BK/GR
2.9L Scorpio BR
7.5L F-Series
7.3L Diesel
3.0L Probe*
All Others BK/LG
* Except 3.0L Probe Test
BK/Y
Pin 60
Test Pin 37/57 VPWR

1.9L MA SEFI W/R
2.9L Scorpio BK
3.0L Probe R/BK
All Others R

ALL RIGHTS RESERVED

Continuous Memory QB
Service Code 15 Test
QB1 ICONDITIONS FOR CONTINUOUS

CODE 15
NOTE: If power is interrupted to the processor, Yes ~ GO to IQB21.

for example when installing a breakout
box, a Code 15 may be present. Rerun No ~ SERVICE other codes
Self-Test to ensure correct diagnosis. as necessary. If none,
testing complete.
Clear Continuous Memory Codes (use procedure
described in Quick Test Appendix).
Is Code 15 present on retest?
QB211NSPECT ENGINE COMPARTMENT WIRING

FOR PROPER ROUTING
Inspect EEC wiring for ~Ioseness to ignition Yes ~ GO to IQB31.

components or wires (High Electrical Energy
Sources). If EEC wiring is close, reroute and rerun No ~ SERVICE other codes
Key On Engine Off Self-Test. as necessary. If none,
testing complete.
Is Code 15 still present 'in Continuous
Memory?
QB3 I CHECK KAPWR CIRCUIT VOLTAGE
Key off, wait 10 seconds. Yes ~ SERVICE open circuit.

for damaged or pushed out pins, corrosion, loose processor. RERUN
REMOVE breakout box.'
Connect positive test lead to Test Pin 1 and RERUN Quick Test.
negative test lead to Test Pin 40 or 60 at the
breakout box.
Key on, engine off.

ALL RIGHTS RESERVED
Output State Check Pinpoint

.QC
Not Functioning Test
INote I
You should enter this Pinpoint Test only when you have been directed here from other
Pinpoint Tests.
IRemember I
Harness circuits: SIG RTN, STO, STI, GND, VPWR, VREF

ALL RIGHTS RESERVED
Output State Check , ,Pinp~int

QC
Not Functioning Test
QC1 I CHECK FOR CODES 23, 53, 63 OR 68
NOTE: If vel1icle is equipped with speed control, Yes ,~ GO to Quick Test and
the speed control servo must be SERVICE appropriate
electrically disconnected. This prevents code as instructed.
the speed control system from affecting
the throttle plate movement during Output Code 11 ~ 'GO to laC21.
State Check. Rerun Quick Test or Output
State Check. No Codes ~ GO to IQA11.
Output State Che'ck, refer to diagnostic
aids in the Quick Test Appendix.
Are any of these codes 23, 53, 63 or 68
present?
QC2 I CHECK THROTTLE LINKAGE
Check throttle and throttle linkages for sticking Yes ~ REPLACE TP sensor.
and binding.' RERUN Qui~k Test.
Is throttle OK? ,
, RERUN Quick Test.
..

ALL RIGHTS RESERVED
Pinpoint
He-Initialization Check
Test
QD
INote I
You should enter this Pinpoint Test only when Service Code 71, 72 or 78 is received
during Quick Test or you have been directed here from Diagnosis By Symptom.
IRemember I
EEC Power Relay
Harness circuits: GND, VPWR, IGNITION

ATO
TEST PIN 40 0- BKlLG - PWR GND ----------..,..----< -v BAn
GND
TEST PIN 60 0- BKlLG PIGTAIL
KEEP ALIVE POWER (KAPWR)
TO
IGN. SW.
TEST PIN 37
-+-IGNITION
0 R-VPWR r
( ~~Hl
S :
I
VEHICLE POWER
GROUND
IGNITION
TEST PIN 57 0- R -VPWR~ TO BATTERY

TO
TEST PIN 1 0 - - KAPWR -------e--~..._-___1 --e::I@ STARTER
MOTOR
TEST PIN 20 0-BK - CASE GND ::L.. TO CHASSIS FUSE RELAY
LINK
TEST PINS LOCATED ON BREAKOUT BOX. ~ GROUND
ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A11506-C

ALL RIGHTS RESERVED
Pinpoint
Test
QD
. Tesf Pin 20 Case GND Test Pin 40/60 PWR GND

2.9L Scorpio BR 1.9L MA SEFI BK/GA
4.0L MA Ranger BK/O 2.9L Scorpio BA
All Others BK 4.9L F-Series/Bronco
Test Pin 1 KAPWR
7.5L F-Series ,
Application Wire Color 7.3L Diesel
3.0L Probe*
2.3L OHe. MA/NON-MA
5.0L SEFI MARK VII All Others BK/LG
5.0L SEFI-MA
*Except 3.0L Probe Test
5.0L EFI. E-Series BK/Y
BK/O Pin 60
7.5L E-Series
7.3L E-Series/Diesel
5.8L E-Series Test Pin 37/57 VPWR
4.9L E-Series
1.9L MA SEFI W/A
4.9L Ranger MA/NON-MA
Y/BK
5.0L Lincon Town Car 2.9L Scorpio BK
2.3L RangerISupercab
All Others R
1.9L MA SEFI BL/A
2.9L Scorpio BK/BL
All Others Y

ALL RIGHTS RESERVED
Re-Initialization Check I Pinpoint I QD

Test '-- ---1
QD1 SERVICE CODE 7.1 or 72:

CHECK FOR SOURCES OF ELECTRICAL
NOISE
A Continuous Memory Code 72 indicates that Yes ~ GO to 10021.

sometime during the last 40 warm-up cycles, power
to the processor was interrupted.
No ~ SERVICE as necessary,
A Continuous Memory Code 71 indicates that RERUN Quick Test.
sometime during the last 40 warm-up cycles the
EEC-IV processor software requested re-initialization
(the execution of data halted and then re-started
from the beginning) which mayor may not result in
a drive complaint.
Possible causes:
Vehicle power interrupted to processor
Noise into processor
- Spark plug wires improperly routed or too close
to the ignition system
- The shielding surrounding the ignition wires
pulled back or removed
- Electrical, radio, or motor noise
- Test Pin 20 (case ground) not grounded to
chassis
- Diodes open on AIC, ISC, relays
NOTE: After-market installed electrical
components may influence the driveability
of the vehicle.
Key off.
Check that the EEC IV wiring and components
are greater than 2 inches from secondary ignition
wires and ignition coil(s).
Check that the EEC IV wiring and components
are greater than 4 inches from distributor, ignition
coil tower(s), starter motor and its wiring.
Are all above conditions satisfied?
QD2 CHECK CASE GND CIRCUIT CONTINUITY

processor. RERUN

ALL RIGHTS RESERVED
Pinpoint
Test
QD
0031 DISCONNECT HARNESS AND CHECK CASE

GROUND

GO to IQ041.
Reconnect processor to breakout box, but For 2.SL CFI:
disconnect vehicle harness from breakout box. GO to IX10/.
REMOVE breakout box~
breakout box and metal case of processor. RERUN Quick Test.
Is the resistance less than S ohms?
QD4 I WIGGLE TEST OF VPWR CIRCUIT

,
Key on, engine off. Yes ~ SERVICE intermittent in

the VPWR circuit.
Connect STAR or VOM to Self-Test connector. RERUN Quick Test.
Self-Test deactivated.
Using Continuous Monitor mode (Engine Running)
No ~ INSPECT EEC power
relay and harness
per Quick Test Appendix observe STAR/VOM for connectors for
indication of a fault while doing the following: damaged pins, loose
- Shake, bend, and twist the EEC harness from wires, corrosion, etc.
the .EEC power relay to the processor.
If OK, REPLACE EEC
Is a fault indicated or does Code 71 reappear in power relay. RERUN
Continuous Memory if the Key On Engine Off Quick Test.
Self-Test is rerun?
QDSI SERVICE CODE 19: INTERNAL VOLTAGE

.
This Service Code 19 indicates the processor's Yes ~ REPLACE EEC
voltage regulator inability to maintain proper internal processor. RERUN
voltage, which is necessary for the processor to Quick Test.
accurately compute data.
.. No ~ SERVICE other codes.
If none, testing
Is 19-10-11 present? complete.

ALL RIGHTS RESERVED
Pinpoint
IKey Power Check Test
QE
INote I
You should enter this Pinpoint Test only when a Service Code 55 is received duringQuick Test.
IRemember I
may be at fault:
Charging system under voltage
Battery charger connected. with engine running
Jump starting
Harness Circuit: KEY PWR

1.9L eFI
R/LG TO
"TEST PIN 5 ( ! ) - - - - - - - K E y PWR ----[E]---~.. IGNITION
SWITCH
RUN POSITION
c:
EEC POWER
RELAY
TEST PINS LOCATED ON BREAKOUT BOX
ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE
A11507-C

ALL RIGHTS RESERVED
IKey Power Check Pinpoint

Test
.QE

2.5L CFI WITH INTEGRATED CONTROLLER
TO
~_- ... IGNITION
SWITCH
CONTROLLER HARNESS CONNECTOR RUN
POSITION
1:\. R1LG
"TEST PIN 5 \ : I - - - - - K E Y POWER - - - - - - - - - '

ALL HARNESS.CONNECTORS VIEWED INTO MATING SURFACE.
A11508-B

ALL RIGHTS RESERVED
Pinpoint
IKey Power Check Test
QE
QE1 ISERVICE CODE 55:

CHECK CONTINUITY OF KEY PWR CIRCUIT
Service Code 55 indicates that the KEY PWR circuit Yes ~ GO to IQE21.
is low.
Possible causes: No ~ SERVICE open circuit.
- KEY PWR Circuit shorted to ground RECONNECT all
components. RERUN
- Faulty processor Quick Test.
Disconnect processor 60 pin connector. Inspe~t
Disconnect the EEC power relay or integrated
controller as appropriate.
For 1.9L CFI:
breakout box and KEY PWR at the EEC power
relay vehicle harness connection.
For 2.5L CFI:
breakout box and Pin 5 at the integrated
controller vehicle harness connector.
QE21 CHECK KEY PWR CIRCUIT FOR SHORT TO

GROUND

EEC power relay or integrated contro.ller RECONNECT all
disconnected. components. RERUN
Breakout box installed, processor disconnected. Quick Test.
Pins 40, 46, and 60 at the breakout box. No ~ SERVICE short circuit.
Is resistance greater than 10,000 ohms? RECONNECT all
components. RERUN
Quick Test.

ALL RIGHTS RESERVED
Pinpoint
Test
s
.1
INote I
You should enter this Pinpoint Test only after a Code 11 is received during Quick Test
and you have been directed here from EEC-IV No-Start Pinpoint Test Step I A20 I or
IRemember I
To prevent the replacement of good components, be aware that the following Non-EEC areas
may be at fault:
Poor power/ground connections
Ignition system distributor cap, rotor, wires, coil, plugs
Base engine valves, cam timing, compression, etc.
This Pinpoint Test is intended only as a Quick Check for the basic functioning of the following:
ISC Bypass Air System
MAp System
EGR System
MAF System

ALL RIGHTS RESERVED
I_S_y_s_te_m_c_._he_C_k 11 Pi;::nt I~_S_--,

IPinpoint Test Flow Chart I
I
PINPOINT PINPOINT
DIAGNOSTIC QUICK
TEST STEP TEST STEP
BY TEST
A20 A20
SYMPTOM STEP
CFI EFI
5.0
~II~ r
GO TO CHECK
ISC BAD NO RPM
CHECK t------... ISC
KE4 DROP
S1 S2
1.9L SEFI GOOD YES
CALIF. ALL OTHERS ,.....---~ SERVICE OPEN VREF CIRCUIT
5.0L MA
GOOD , - - - - - - - - - - ,
I' POWER TO L.oOB~A_D_---, MAP/BP BAD
QUICK
MAP/BP
CHECK
.....
GOOD GOOD ALL OTHERS/,,--
~ OUTPUT
CHECK .
11t
t--~~-~L.---I-~S3~----1..., I
TEST
STEP I \.\./f\-J VAF AND MAF
I
S4 REPLACE
MAP/BP
-- --
3.0
GOOD ALL OTHERS
GO TO MAP .........
EGR 1-- -..1 APPRO- DYNAMIC SENSOR
VACUUM RESPONSE. VACUUM
PRIATE TEST en
S8 EGR
i
L..-G-O-O-D-A-LL-O-if-H-ER-S....
S6 ~
'---...,--
0
~
S5
NO
REPLACE
VACUUM MAP
GO TO
EGR LINES
VALVE I---:B~A~D~---'~ SECTION
CHECK
6
S9 57
GOTO
GOOD
!
REPLACE
!~
SERVICE
PINPOINT MAP/BP VACUUM
TEST LINES
H
A9693-F

ALL RIGHTS RESERVED
Pinpoint
ISystem Check Test
s
~
I
S1 IISC-SPA CHECK
NOTE: This Test Step' is for EFI/SEFI vehicles Yes ~ GO to IKE41.

with stalls and or no starts.
For CFI vehicles go directly to Isal . No ~ GO to 15al.
Attempt to start engine at part throttle.
Will engine run smooth at part throttle?
S2 I CHECK FOR RPM DROP .-
NOTE: This Test Step is for EFI/SEFI vehicles Yes ~ RECONNECT ISC
only. For CFI vehicles, go directly to Isal. solenoid. GO to Isal.
Key off.
No ~ GO to IKE41.
Connect engine tachometer.
Start engine. .
Disconnect ISC solenoid.
Does rpm drop or stall?
S3 I POWER TO MAP/SP SENSOR TEST
NOTE: If the vehicle being checked is not Yes ~ GO to 1541.

equipped with MAPIBP system hardware
go directly to Isal. Green light on tester No ~ SERVICE open VREF
indicates VREF is OK. Red Light (or no circuit. REMOVE
light) indicates VREF is either too low or MAP/BP tester.
too high. RECONNECT MAP/BP.
RE-EVALUATE
Key off. symptom.
Disconnect the MAP/BP sensor from the vehicle
harness.
Connect the MAP/ BP tester between the vehicle
harness and the MAP/BP sensor, (refer to
schematic below).
Insert MAP/BP tester banana plugs into DVOM.
Set DVOM to 20 volt scale.
Key on, engine off.
Is green light on?

ALL RIGHTS RESERVED
Pinpoint
ISystem Check Test
s
POWER TO MAP/BP SENSOR TEST

S3
(Continued)
*TEST PIN 46 (!) SIG RTN

TEST PIN 45 G> MAP/BP SIG
I ~
-
..
"lJ
"n
I ~
TEST PIN 26 e VREF MAP/BP SENSOR
VEHICLE
HARNESS
CONNECTOR
1m D
TO MAP/BP
SENSOR
TO
MAP/BP
.
TO DVOM
IJ
VEHICLE SENSOR
HARNESS
CONNECTOR
~>
a: ~
--- tS1A
a..CC
~{)
c
a:
a -,,-
mw
a..(J)
<w
u.
a.. > :EI- + t::::>

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A9588D

ALL RIGHTS RESERVED
ISyste~ Check Pinpoint

Test
s
TEST STEP RESULT .. ~ ACTION TO TAKE
S4 I MAP/BP TESTER OUTPUT READING
NOTE: Measure several known good MAPIBP Yes ~ For vehicles with
sensors on available vehicles. The Vane Air Flow Meters
measured voltage will be typical for your or Mass Air Flow
location on the day of testing. sensors:
GO to Isal.
MAP I BP. Tester and DVOM connected.
For all others:
DVOM or 20 volt scale. GO to Issl.
Key on.
. Approximate Altitude Voltage Output No (Sensor ~ REPLACE MAPIBP
(Ft.) (+1- .04 Volts) output is out-of- sensor.
range)
0 1.59
1000 1.56 t
2000 1.53
3000 1.50
4000 1.47
5000 1.44
6000 1.41
7000 1.39
Is voltage in range for your altitude?
S5 I CHECK MAP SENSOR
Key off, wait 10 seconds. Yes ~ RELEASE vacuum.

REMOVE vacuum
Disco'nnect vacuum line from MAP sensor. pump. RECONNECT
Install vacuum pump to MAP sensor. vacuum line to MAP
sensor. GO to Is61 .
Apply 18 in-Hg vacuum to MAP sensor.
Does MAP sensor hold vacuum? No ~ REPLACE MAP sensor.
RECONNECT vacuum
line to MAP sensor.
RERUN Quick Test.
S6 I MAP ENGINE RUNNING RESPONSE TEST
Key on Yes ~ GO to Isal.

MAP/BP Tester and DVOM connected.
No ~ GO to IS71.
Crank engine.
While cranking, does MAP output voltage
change any amount?

ALL RIGHTS RESERVED
Pinpoint
ISystem Check Test
s
TEST STEP RESULT' ~ ACTION TO TAKE
S7 I CHECK VACUUM LINES
Check vacuum lines for proper routing. Refer to Yes ~ REPLACE MAP sensor.
VECI decal. Check MAP sensor vacuum line for REMOVE MAP/BP
holes, disconnections, kinks or blockage. tester. REEVALUATE
symptom.
Are vacuum lines OK?
No ~ SERVICE vacuum lines
as necessary. RERUN
Quick Test.
S8 I CHECK EGR VACUUM
NOTE: If the vehicle being checked is not Yes ~ For 1.9L EFI:
equipped with EGR system hardware, go GO to IKA11.
directly to [HI]. The next two test steps
will attempt to determine if the EGR For 2.3L OHC EFI
system is the cause of the current Car:
GO to 100111.
symptom and/or NO START.
Disconnect vacuum line at EGR valve. Do not For 2.3l OHC MA EFI,
plug the vacuum line. 2.Sl HSC CFI, S.Ol
SEFI Car and 2.3l
Start engine. OHC EFI 4.9l EFI,
For Drive Symptom: S.Ol EFI, S.8l EFI,
7.SL EFI Truck:
- While at idle, is vacuum present at vacuum GO to ION421.
line?
For 1.9l CFI, 2.3l
For No Start: HSC, EFI, 2.9l EFI,
- Does engine start? 3.0L SHO, 3.0L EFI
and 3.8l SEFI Car:
GO to IOl21 I.
No ~ GO to 1891.
S9 I CHECK EGR VALVE
Inspect EGR valve to ensure proper seating. Yes ~ GO to [HI].

Is EGR valve fully seated (closed)?
No ~ GO to Section 6 of
this Manual for EGR
valve diagnosis.

ALL RIGHTS RESERVED
Pinpoint
ITransmission - AXOn. Test
T
INote I
You should enter this Pinpoint Test only when Service Code 29, 39, 57, .59, 62, 67, 68,
69 or 89 is received during Quick Test.
IRemember I
may be at fault:
Basic AXOD transmission problems
,. Harness circuits: THS 4/3, THS 3/2, TTS, LUS, NPS, VSS DIF(+), VSS DIF( -)' and VPWR
Vehicle Speed ~ensor (-9E731-)

ALL RIGHTS RESERVED
1_~--------iIIPi;TnPes~tint~
Transmission-AXOn . ~_
j
AXOD - HARNESS CONNECTIONS
-TEST PIN 18 @~DG;",,;;,;,;,,;./P THS 4 / 3 - - - - - - - -

TESTPIN9 GYNI
(3.8L ONLY) @ TIS AXOD
TEST PIN 37/57@ ~ VPWR 0 VEHICLE HARNESS
TEST PIN 19 @ T/LB THS 3/2 _ CONNECTOR
TeST PIN 53 @ pN LUS---------
TEST PIN 30 @ NPS--------
VEHICLE
SPEED
TEST PIN 6
TEST PI~ 3 ~:
....."O".."N~_-VSS DIF (_)
DGNI .
VSS DIF (+ ) - - - - - - - . .
/"
11 SENSOR (VSS)
VEHICLE
HARNESS
CONNECTOR
AXOD - FUNCTIONAL AXOD

r o
- - - - - - - - - - ,
I
TEST PIN 9 ~L.. TIS
(3.8L ONLY) @----TIS-------~/I)
~~
';:b~~~D
TEST PIN 18 @ - - - - T H S 4/3 )1)----.
TEST PIN 19 @ THS 3/2 )!r--. ~~
~ ~::
TEST PIN 30
TEST PIN 53
I
> CASE
I GROUND
TEST PIN 37/57 @ VPWR ~-. LOCK-UP
I SOLENOID
I
I
I
TeST PIN 6 @ _ - - - V S S DIF (-)-----~)l>_ VEHICLE
I SPEED
TeST PIN 3 0 - VSS DIF (+ )-----~)i>--SENSOR
I
I~ J

A9694-E

ALL RIGHTS RESERVED
E~CIV Pinpoint Test Procedures 17-399
Pinpoint
ITransmission - AXOn
Test
T
AXOD Transmission Drive Cycle

NOTE: All components must be connected when performing this test.
1. Record and clear Continuous Memory Self-Test codes.
2. Warm engine to operating temperature.
3. With transmission in D range, lightly accelerate from a stop to 40 mph to achieve third
, gear. Hold speed and throttle opening (not closed throttle) steady for 15 seconds minimum
(30 seconds above 4000 feet altitude).
4. Shift gear selector to 00 range and accelerate lightly from 40 to 50 mph to achieve !
fourth gear. Hold speed and throttle opening (not closed throttle) steady for 15 seconds
minimum in fourth gear.
5. With transmission in fourth gear and steady speed and throttle opening (not closed
throttle) lightly apply and release brakes (to light brake lamps) and then hold speed and
throttle opening steady for an additional 15 seconds minimum.
"
6. Brake to a stop and remain stopped for 20 seconds minimum with transmission in OD
range.
7. Turn engine off. Run Key On Engine Off Self-Test and record Continuous Memory Codes.
T1 CONTINUOUS MEMORY CODE 29:

ATTEMPT TO GENERATE CONTINUOUS
MEMORY CODE 29
Continuous Memory Code 29 indicates that there is Yes ~ GO to 1121.

insufficient input to the processor from the Vehicle
Speed Sensor. . No ~ Unable to duplicate
NOTE: For 3.0L Probe, GO to IDP11 . and/or identify fault at
Possible causes are: diagno'sis using the
EEC-IV Monitor box,
- Faulty Vehicle Speed Sensor REFER to Section 18
- Open or shorted <?ircuit EEC-IV Monitor Box:
Intermittent Fault
- Faulty processor ..''Diagnosis.
Perform AXOD Transmission Drive Cycle, then All others, CLEAR
return to this Step. Continuous Memory
Did Continuous Memory Code 29 repeat? (REFER to Quick Test
Appendix). RERUN
Quick Test.

ALL RIGHTS RESERVED
ITransmi~sion ~ AXOn Pinpoint

Test
T
T2 ICHECK CONTINUITY OF VEHICLE

SPEED SENSOR (VSS) CIRCUITS

Disconnect Vehicle Speed Sensor (VSS).
No ~ SERVICE open
Disconnect processor 60 pin connector. Inspect circuit(s). REMOVE
for damaged or pushed out pins, corrosion, loos~ breakout box.
~ Install breakout box, leave processor disconnected. components. REPEAT
Test Step ITIJ .
breakout box and VSS DIF(+) circuit at the VSS
breakout box and the VSS DIF( -) circuit at the
VSS vehicle harness connector.
TEST PIN 6
TEST PIN 3
e--- VSS
e--- VSS DIF (-)
DIF ( + )
~.:
~
A9695-B
T3 ITO
CHECK VSS CIRCUITS FOR SHORTS
POWER OR GROUND

RECONNECT all
VSS disconnected. components. GO to
Breakout box installed, processor disconnected. 1141.
No ~ SERVICE short
Pins 37, 40 and 6 at the breakout box. circuit(s). REMOVE
breakout box.
Pin 37 at the breakout box. components. REPEAT
Is each resistance greater than 10,000 ohms? Test Step 1111.

ALL RIGHTS RESERVED
Pinpoint
ITransmission - AXOD
Test
T
T4 REPEAT DRIVE CYCLE WITH A KNOWN GOOD

VSS INSTALLED
Substitute VSS with known good sensor. : Yes ~ REPLACE processor.

REINSTALL original
Processor and VSS connected. VSS. REPEAT Test
Perform AXOD Transmission Drive Cycle (outlined Step IT11.
at the beginning of this Pinpoint Test), then return
to this Step. No ~ REPLACE original VSS.
RERUN Quick Test.
Did Continuous Memory Code 29 repeat?
. T10 CONTINUOUS MEMORY CODE 69:

MEMORY CODE 69
Continuous Memory Code 69 indicates that the Yes ~ GO to IT111.

AXOD THS 3/2 pressure switch circuit failed open.
Possible causes are: No ~ Unable to duplicate
- Open or short in THS 3/2 circuit. this time. For further
diagnosis using the
- Faulty processor. EEC-IV Monitor box,
- AXOD THS 3/2 pressure switch problem. REFER to Section 18
EEC-IV Monitor Box:
Perform AXOD Transmission Drive Cycle outlined Intermittent Fault
at the beginning of this Pinpoint Test). then return Diagnosis.
to this Step.
All others, CLEAR
Did Continuous Memory Code 69 repeat? Continuous Memory
Appendix). RERUN
Quick Test.
"
..

ALL RIGHTS RESERVED
Pinpoint
Test
T
TESTSTEP RESULT ~ ACTION TO TAKE
T11 I CHECK CONTINUITY OF THS 3/2 CIRCUIT
Key off. Yes ~ GO to IT121.

Disconnect AXOD vehicle harness.
Disconnect processor 60 pin connector. Inspect No ~ SERVICE open in THS
for damaged or pushed out pins, corrosion, loose 3/2 circuit. REMOVE
components. REPEAT
DVOM on 200 ohm scale. Test Step IT10 I.
breakout box and THS 3/2 circuit at the AXOD
~
TEST PIN 19
0 THS 3/2 0
A9696-C
T121 CHECK THS 3/2 CIRCUIT FOR SHORT TO

POWER
Key off. Yes ~ GO to IT13/.

AXOD vehicle harness disconnected.
Breakout box installed, processor disconnected. No ~ SERVICE short to
DVOM on 200,000 ohm scale. power in THS 3/2
circuit. REMOVE
Measure resistance between Test Pin 19 and Test breakout box.
Is resistance greater than 10,000 ohms? components. REPEAT
Test Step IT10 I.
T13 I CHECK PROCESSOR OPERATION

Reconnect AXOD vehicle harness. REMOVE breakout box.
RECONNECT
Breakout box installed. processor. GO to
Connect processor to breakout box. Transmission Shop
Jumper Test Pin 19 to Test Pin 40 at the Manual Group for
breakout box. . AXOD Transmission
Electrical Component
diagnosis.
REMOVE jumper wire.
REPEAT Test Step
IT101.

ALL RIGHTS RESERVED
Pinpoint
Test
T
T20 CONTINUOUS MEMORY CODE 59:

MEMORY CODE 59
Continuous Memory Code 59 indicates that the Yes ~ GO to IT211.

AXOD THS 4/3 pressure switch ci'rcuit failed open.
Possible causes are: No ~ Unable to duplicate
- Open or short in THS 4/3 circuit.
-.
diagnosis using the~'
~ Faulty processor. EEC-IV Monitor box,
- AXOD THS 4/3 pressure switch problem. REFER to Section 18
EEC-IV Monitor Box:
Perform AXOD Transmission Drive Cycle (outlined Intermittent Fault
at beginning of this Pinpoint Test), then return to Diagnosis.
this Step.
All others, CLEAR
Did Continuous Memory Code 59 repeat? Continuous Memory
Appendix). RERUN
Quick Test.
T21 CHECK CONTINUITY OF THS 4/3 CIRCUIT

No ~ SERVICE open in THS
Disconnect processor 60 pin connector. Inspect 4/3 circuit. REMOVE
for damaged or pushed out pins, corrosion, loose breakout box.
components. REPEAT
Install breakout box, leave processor disconnected. Test Step IT20 1.
breakout box and THS 4/3 circuit at the AXOD
TEST PIN 180
THS~3CiE
0
A9697B
Is resist~nce less than 5 ohms?
'.'

ALL RIGHTS RESERVED
Pinpoint
ITransmission - AXOD Test
T
T22 ICHECK THS 4/3 CIRCUIT FOR SHORT TO

POWER

Breakout box installed, processor disconnected. power in THS 4/3
circuit. REMOVE
Test Step IT20 I.

Reconnect AXOD vehicle harness. RECONNECT
Transmission Shop
Connect processor to breakout box. Manual Group for
AXOD Transmission
Jumper Test Pin 18 to Test Pin 40 at the Electrical Component
breakout box. Diagnosis.
Is Code 62 or 59 present? No ~ REPLACE processor.
REMOVE jumper wire.
REPEAT Test Step
IT201.

ALL RIGHTS RESERVED
Pinpoint
Test
T
T30 I
TEST STEP
CONTINUOUS MEMORY CODE 39:

Continuous Memory Code 39 indicates that the .

AXOD transmission converter bypass clutch (lock-up)
is not operating properly.
Yes . GO to Transmission
Group in Shop Manual
for AXOD Transmission
NOTE: If Continuous Memory Code 59 is also diag~osis.
present, go directly to 1T20 I.
Perform AXOD Transmission Drive Cycle (outlined
at the beginning of this Pinpoint Test), then return
to this Step.
No . Unable to duplicate
diagnosis using the
Did Continuous' Memory Code 39 repeat? EEC-IV Monitor box,
REFER to Section 18
EEC-IV Monitor Box:
Intermittent Fault
Diagnosis.
All others, CLEAR

Continuous Memory
Appendix). RERUN
, Quick Test.
T40 ICONTINUOUS MEMORY CODE 57:

Continuous Memory Code 57 indicates that the

AXOD Neutral Pressure Switch (NPS) has failed
open.
Yes
No
.. GO to IT411.
Unable to duplicate
Possible causes are: and/or identify fault at
- Open or short in NPS circuit. diagnosis using the
EEC-/V Monitor box,
- Faulty processor. REFER to Section 18
- AXOD NPS problem. EEC-IV Monitor Box:
Intermittent Fault
Perform AXOD Transmission Drive Cycle (outlined Diagnosis.
at the beginning of this ,Pinpoint Test), then return
to this Step. All others, CLEAR
Continuous Memory
Did Continuous Memory Code 57 repeat? (REFER to Quick Test
Appendix). RERUN
,
Quick Test.

ALL RIGHTS RESERVED
Pinpoint
ITransmission - AXOn Test
T
T41 I CHECK CONTINUITY OF NPS CIRCUIT

Disconnect processor 60 pin connector. Inspect No ~ SERVICE open in NPS
for damaged or pushed out pins, corrosion, loose circuit. REMOVE
components. REPEAT
DVOM on 200 ohm scale. Test Step IT40 1.
breakout box and NPS circuit at the AXOD
TEST PIN 3O@---NPS Jt A9698B
T42 I CHECK NPS CIRCUIT FOR SHORT TO POWER

Breakout box installed, processor disconnected. No ~ SERVICE short to
DVOM on 200,000 ohm scale. power in NPS circuit.
Is resistance greater than 10,000 ohms? Test Step IT40 1.

Reconnect AXOD vehicle harness. REMOVE breakout box.
RECONNECT
Connnect processor to breakout box. Transmission Shop
Jumper Test Pin 30 to Test Pin 40 at the Manual Group for
breakout box. AXOD Transmission
Run Key On Engine Off Self-Test. Electrical Component
diagnosis.
Is Code 67 present? ,
REMOVE jumper wire.
REPEAT TEST Step
IT401.

ALL RIGHTS RESERVED
Pinpoint
T
T50 ISERVICE CODE 89:

CHECK CONTINUITY OF VPWR CIRCUIT
Service Code 89 indicates that the AXOD Yes ~ GO to IT511 .

. transmission Lock-Up Solenoid (LUS) circuit failed -
always open or always closed.
Possible causes are: VPWR circuit to AXOD.
- Open or shorted circuit REMOVE breakout box.
RECONNECT all
- Faulty processor components. RERUN
- AXOD LUS problem Quick Test.
Key off.
wires etc. Service as necessary.
breakout box and VPWR circuit at the AXOD
TEST PIN 37<!r---VPWR
A9699-C
T51 I CHECK CONTINUITY OF LUS CIRCUIT

AXOD vehicle harness disconnected. -
Breakout qox installed, processor disconnected. No ~ SERVICE open in LUS
circuit to AXOD.
Measure resistance between Test Pin 53 at the RECONNECT all
breakout box and LUS circuit at the AXOD vehicle components. RERUN
TEST PIN 530~--.LUS~

~
A9700-C

ALL RIGHTS RESERVED
Pinpoint
T
T52 I CHECK LUS CIRCUIT FOR SHORT TO POWER

OR GROUND

No ~ SERVICE short in LUS
circuit. REMOVE
RECONNECT all
Pins 37 and 40 at the breakout box. Quick Test. If code 89
Is each resistance greater than 10,000 ohms? is still present,
REPLACE processor.
RERUN Quick Test.
T53 I CHECK TOTAL CIRCUIT RESISTANCE

Reconnect AXOD vehicle harness. RERUN Quick Test.
DVOM on 200 ohm scale. No ~ REMOVE breakout box.
RECONNECT
Measure the resistance between Test Pin 53 and processor. GO to
Test Pin 57 at the breakout box. Transmission Shop
Is resistance between 20 ohms and 40 ohms? Manual Group for
AXOD Transmission
diagnosis.
T60 I SERVICE CODE 62:

CHECK AXOD VEHICLE HARNESS OPERATION -
Service Code 62 indicates that the AXOD THS 4/3 Yes ~ GO to IT6~1.
or 3/2 pressure switch circuit failed closed.
Possible causes are: No ~ RECONNECT AXOD
vehicle harness. GO to
- Short in THS 4/3 or THS 3/2 circuit. Transmission Shop
- Faulty processor. Manual Group for
AXOD Transmission
- AXOD THS 4/3 or THS 3/2 pressure switch Electrical Component
problem. diagnosis.
Key off.

ALL RIGHTS RESERVED
Pinpoint
ITransmission - AXOD .T
I Test
T61 I
CHECK THS 3/2 AND 4/3 CIRCUITS
FOR SHORT TO GROUND
Key off. Yes ~ . REPLACE processor.

AXOD vehicle harness disconnected. REMOVE breakout box.
RECONNECT all
Install. breakout box, leave processor disconnected. No ~ .SERVICE short to
DVOM on 200,000 ohm scale. ground. REMOVE
breakout box.
Pins 40 and 60 at the breakout box. components. RERUN
T70 I
SERVICE CODE 59:
CHECK AXOD VEHICLE HARNESS
Service Code 59 indicates that the AXOD THS 4/3 Yes ~ GO to IT711.
pressure switch circuit failed closed.
- Short in THS 4/3 circuit. vehicle harness. GO to
Transmission Shop
--"- Faulty processor. Manual Group for
- ' AXOD THS 4/3 pressure switch problem. AXOD Transmission
Key off. diagnosis.
T71 I
CHECK THS 4/3 CIRCUIT FOR SHORT TO
GROUND

t'I
AXOD vehicle harness disconnected. RECONNECT AXOD
Disconnect processor 60 pin connector. Inspect vehicle harness.
Install breakout box, leave processor disconnected. No ~ SERVICE short to
DVOM on 200,000 ohm scale. ground. REMOVE
breakout box.
Measure resistance between Test Pin 18 and Test RECONNECT AXOD
Pins 40 and 60 at the breakout box. vehicle harness and
Is each resistance greater than 10,000 ohms? processor. RERUN
Quick Test.

ALL RIGHTS RESERVED
I~T_r_a_n_sm_i_SS_i_o_n_-_AX_O_D 1[ Pi;:::nt I L..--_

T
_---'
T75 ISERVICE CODE 69:

CHECK AXOD VEHICLE HARNESS
Service Code 69 indicates that the AXOD THS 3/2 Yes ~ GO to IT761.
pressure switch circuit failed closed.
vehicle harness. GO to
- Short in THS 3/2 circuit. Transmission Shop
Manual Group for
- Faulty processor. AXOD Transmission
- AXOD THS 3/2 pressure switch problem. Electrical Component
diagnosis.
Key off.
T761 CHECK THS 3/2 CIRCUIT FOR SHORT TO

GROUND

AXOD vehicle harness disconnected. RECONNECT AXOD
Disconnect processor 60 pin connector. Inspect vehicle harness.
RERUN Quick Test.
ground. REMOVE
RECONNECT AXOD
Measure resistance between Test Pin 19 and Test vehicle harness and
Pins 40 and 60 at the breakout box. processor. RERUN
Quick Test.
.
,.

ALL RIGHTS RESERVED
Pinpoint
.1 Transmission - AXOD T
Test
T80 SERVICE CODE 67:

TEST STEP
CHECK VOLTAGE AT NPS INPUT TO

RESULT'
.'. ACTION,TO TAKE
PROCESSOR
Service Code 67 indicates that either the AXOD Yes ~ GO to IT811.

Neutral Pressure Switch (NPS) circuit failed closed,
or the input to the AIC clutch circuit is closed. No ~ GO to Pinpoint Test
NOTE: For 3.0L Probe, go to I FA 11 . IFA101.

- Short in NPS circuit.
- Short in AIC clutch circuit (3.0L EFI only).
- AIC on during Self-Test (3.0L EFI only).
- Faulty processor.
- AXOD NPS problem.
Key off.
wires etc. Service as necessary.
breakout box.
Key on, engine off.
Is Yoltage less than 4 Yolts?
T8l CHECK NPS HARNESS CIRCUIT FOR SHORT

TO GROUND

Breakout box installed. ground in NPS circuit.
RECONNECT all
Quick Test.
Is each resistance greate~ than 10,000 ohms?

ALL RIGHTS RESERVED
17--412 EECIV Pinpoint Test Procedures
__O_D
I..T_r_a_D_S_m_i_S_Sl_.O_D_-_AX ----'11 Pi;::nt I'---_T_---"
.. TEST STEP RESULT ~ ACTION TO TAKE
T82 I PROCESSOR VERIFICATION

AXOD vehicle harness disconnected. RECONNECT all
Breakout box installed. components. RERUN
Quick Test.
Run Key On Engine Off Self-Test. No ~ REMOVE breakout box.
Is Code 67 present? RECONNECT all
components. GO to
Transmission Shop
Manual Group for
AXOD Transmission
diagnosis.
T90 ICHECK
SERVICE CODE 68:
CONTINUITY OF TIS CIRCUIT
Service Code 68 indicates that the AXOD Yes ~ GO to IT911.

Transmission Temperature Switch (TTS) failed open.
Possible causes are: No ~ SERVICE open in TIS
circuit. REMOVE
- Open or short in TIS circuit.
breakout box.
- Faulty processor. RECONNECT all
components. RERUN
- AXOD TIS problem. Quick Test.
Key off.
breakout box and TTS circuit at the AXOD vehicle
harness connector.
TEST PIN 9 0
ns _ _
A11542-B

ALL RIGHTS RESERVED
EECIV Pinpoint Test Pro'cedures 17413
ITransmission - AXOD .
Pinpoint
Test
T
T91 I CHECK TIS CIRCUIT FOR SHORT TO POWER

No ~ SERVICE short in TTS
AXOD vehicle harness disconnected. circuit. REMOVE
breakout box.
Pin 37 at the breakout box. Quick Test.
Is' resistance greater than 10,000 ohms?

REMOVE jumper wire.
RECONNECT AXOD vehicle harness. REMOVE breakout box.
Breakout box installed. RERUN Quick Test.

No ~ REMOVE jumper wire.
Jumper Test Pin 9 to Test Pin 40 at the breakout REMOVE breakout box..
box. RECONNECT
processor. GO to
Run Key On Engine Off Self-Test. Transmission Shop
Is Code 68 still present? Manual Group for
AXOD Transmission
diagnosis.

ALL RIGHTS RESERVED
Pinpoint
ITransmission - A4LD Test
TB
INote I
You should enter this Pinpoint Test only when a Service Code 86 or 89 Is received
during Quick Test.
IRemember I
may be at fault:
Hydraulic brakes Internal transmission

Emergency brakes Transmission linkage
Harness circuits: CCO, SS 3/4-4/3 and Shift Solenoid 3/4-4/3 (-6916-).

VPWR.
Processor Assembly (-12A650-).
CCO Solenoid (-6916-).

TEST PIN 52f
PIN 37
PIN 57
T/~B 55
R _ VPWR ~++--+4
t-+I~--_SS
1---+-+-+--- VPWR
I-+t~~-- ceo
PIN 53 ceo - .......+4
A4LD
A4LD TRANSMISSION TRANSMISSION
VEHICLE HARNESS BUL.KHEAD CONNECTOR
CONNECTOR
NOTE: SS 3/4-4/3 IS NOT USED ON 2.3L OHC, 49 STATES MUSTANG

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. A9202-B
Test Pin 53 ceo Solenoid

Car: 2.3L OHC O/Y
Truck:
2.3L, 2.9L, 3.0L W

ALL RIGHTS RESERVED
ITransmission ~ A4LD Pinpoint

Test
TB
181 I SERVICE CODE 86 or 89:

CHECK RESISTANCE OF SOLENOIDS
Service Code- 86 indicates the processor did not Yes ~ GO to ITB41.

see a voltage drop when the Shift Solenoid (55)
was activated.
No ~ GO to ITB21.
Service Code 89 indicates the processor did not
see a voltage drop when the CCO solenoid was
activated.
- CCO/SS resistance out of limits
- CCO/SS circuit open or grounded
- Faulty processor
Verify Self-Test code match with appropriate
transmission solenoid circuit below:
Processor
Signal Output KOEO Self
Solenoid Pin Test Code
CCO 53 89
SS 3/4 52 86
ceo - Converter Clutch Override
SS 3/4 Shift Solenoid 3/4-4/3

Install brea~out box, leave processor disconnected.
Measure the resistance between Test Pin 37/57 ,
and processor signal output pin (refer to table) at
the breakout box.
Is the resistance between 26 and 40 ohms?

ALL RIGHTS RESERVED
Pinpoint
ITransmission - A4LD Test
TB
T821 CHECK CONTINUITY OF VEHICLE HARNESS

CIRCUITS
Key off. Yes ~ GO to IT831:

A4LD transmission bulkhead connector REMOVE breakout box.
disconnected. RECONNECT all
components. RERUN
Measure the resistance between Test Pins 37/57
at the breakout box and VPWR circuit at the
A4LD transmission vehicle harness connector.
Measure the resistance between the processor
signal output pin (refer to table in IT811) at the
breakout box and the same circuit at the A4LD
transmission vehicle harness connector.
T831 CHECK A4LD TRANSMISSION VEHICLE

HARNESS CIRCUITS

No ~ SERVICE short
A4LD transmission bulkhead connector circuit(s). REMOVE
disconnected. breakout box.
RECONNECT all
Measure the resistance between the processor Quick Test.
signal output pin (refer to table in IT8 11) and
Test Pins 37/57 at the breakout box.
signal output pin (refer to table in 1T811) and
Test Pins 40, 60 and 46 at the breakout box and
chassis ground.

ALL RIGHTS RESERVED
Pinpoint
ITransmission - A4LD
Test
TB
T841 CHECK VPWR VOLTAGE TO A4LD

TRANSMISSION SOLENOIDS
Key off. .ves ~ GO to ITBSI.

Connect processor to breakout box. REMOVE Breakout box.
RECONNECT
A4LD transmission bulkhead connector solenoid(s). RERUN
disconnected. Quick Test.
Key on, engine off.
Measure voltage between Test Pins 37/57 at the
A4LD transmission vehicle harness connector and
chassis ground/battery ground.
T85 I CHECK OUTPUT DRIVER SIGNAL
Key off. Yes ~ Problem is internal to

the transmission. Go to
Breakout box installed, processor connected. Transmission Group in
A4LD transmission bulkhead connector Shop Manual for A4LD
disconnected. transmission service.
Connect test light between Test Pin 37/57 and

signal output pin (refer to table in ITB11 .at the
breakout box. RECONNECT
Enter Key On, Engine Off Self-Test. solenoid(s). RERUN
Quick Test.
Does test lamp flash momentarily then stay
off?

ALL RIGHTS RESERVED
I.....T_r_a_D_Sm_iS_S_i_O_D_-_E_4_0_D 11 Pi;:::nt I T_ L..-_

C
_---'
INote I
You should enter this Pinpoint Test only when Service Codes 26, 47, 56, 66, 67, 91, 92,
93, 94, 97, 98 and 99 are received in Quick Test Step 3.0 and/or Service Codes 26 and
65 are received in Quick Test Step 5.0 and/or Service Codes 29, 49, 56, 59, 62, 66, 69
and 99 are received in Quick Test Step 6.0 or when directed here from Diagnosis By
Symptom.
IRemember I
Be aware that the E40D transmission solenoid assembly (-7G391-) and the Manual lever
Position (MlP) sensor (-7F293-) are not analyzed in this Pinpoint Test diagnostics, but are
analyzed in Transmission Shop Manual Group.
Harness circuits: GGG, GGS, 4X4 lOW, EPG, OGll, OCS, SS1, SS2, SIG RTN, TOT, MlP,
EPC PWR, and VPWR.
Processor Assembly (-12A650-) or (-128565-) on 7.3l Diesel.

E40D VEHICLE HARNESS SCHEMATIC
*TEST PIN 42 0 O/BK TOT

(TEST PIN 7 - 7.3L DIESEL)
TEST PIN 46 0 BKNJ SIG RTN
TEST PIN 55 0 BR CCS
TEST PIN 53 0 PIW CCC E40D

TRANSMISSION
VEHICLE
TEST PIN 52 0 DIY SS1
HARNESS
CONNECTOR
TEST PIN 38 0 LBIY EPC
TEST PIN 19 0 DGJR SS2
TEST PIN 37/57 0 EPCPWR

TEST PIN 37/57 0 R VPWR

A 1282o-a
Test Pins 35 & 37/57 EPCPWR

7.3L Diesel Y/W
4.9L, 5.8L & 7.5L R or R/W

ALL RIGHTS RESERVED
' Pinpoint I
""-T_r_a_n_sm_is_s_i_o_n_-_E_4_0_D_______ , ---'_T_e_s_t_--, ,--_T_C_......
I
IPinpoint Test Schematic I .

E40D SOLENOID ASSEMBLY
r------ --- -- - --- -----------
TEST PIN 52 o--ON----SS1--~. >----
II SHIFT
SOLENOID
TEST PIN 19 o--DG/P---SS2--.~ >---

SHIFT
II SOLENOID
TEST PIN 38 o - - L B N - - - - E P C - -... ~-

ELECfRONIC
II PRESSURE
CONTROL
SOLENOID
TEST PIN 35 o--Y/W--- EPCPWR ~
(7.3L DIESEL ONLY)
TEST PIN 53 e>--PN----CCC ..
CONVERTER
II CLUTCH
SOLENOIO
TEST PIN 55 0 - - - BR - - - - CCS ---.... > - - -

COAST
II CLUTCH
SOLENOID
TEST PIN 37/57 0- R -VPWR& EPC PWR ~ I >-----------'
TESTPIN42 o---O/BK---TOT---
TRANSMISSION
I OIL
I ~ TEMPERATURE
11;
I
I
TESTPIN46 ~BKJW--SIGRTN-:>
L
~ - SENSOR
- _- - - - - - - - - - - - -
I
-I
A12821-A

ALL RIGHTS RESERVED
Pinpoint
ITransmission - E40D Test
TC

MANUAL LEVER POSITION (MLP) VEHICLE HARNESS SCHEMATIC
-TEST PIN 30 0 - - - - - LBfW - - - - - M L P - - - - _ . MLP

SENSOR
TEST PIN 46 0 - - - - - BKf\N - - - - - SIG RTN - - - - - - . .....oWI VEHICLE
HARNESS
CONNECTOR
A 12822-B
4 x 4 LOW AND OVERDRIVE CANCEL VEHICLE HARNESS SCHEMATIC
TEST PIN 12 "'0--LB/BK - - 4 . 4 LOW

n_~_~_~w ~
J I
__
J.,..-f-----....- ..... TO KEYPWR
4x4LOWLED
TEST PIN 32 0 - - LGIW OCIL---....... l J_..+----..---....I

OCILLED
TEST PIN 41 0 - - T/LS - - - OCS---<)

OVERDRIVE
CANCEL
SWITCH A12823-B


ALL RIGHTS RESERVED
Pinpoint
ITransmission - E40D
Test
TC
TC 1 I
TEST STEP
SERVICE CODE 67:

CHECK RESISTANCE OF THE MLP SENSOR
Service Code" 67 indicates that the total resistance

within the Manual Lever Position (MLP) sensor is
out of Self-Test range when the selector lever is in
PARK (correct range is 3770 to 4607 ohms).
Yes
No
. GO to ITC31.
GO to ITC21 .
- Faulty or misadjusted MLP sensor
-. Open or shorted harness
- Faulty processor
Disconnect processor 60 pin connector. Inspect ,
Unlock steering column, ignition off.
Measure and record resistance between Test Pin
30 and 46 at the breakout box in each selector
position while moving the selector from Park to
Low and back "to Park position. Refer to MLP
Sensor Resistance Specification Table # 1.
Is each resistance within specifications?
Manual Lever Position (MLP) Sensor

Resistance Specification Table # 1
Resistance
Transmission Shift . (ohms)
-Position
Rmin Rmax
p 3770 4607
R 1304 1593
N 660 807
0 361 442
2 190 232
1 78 95

ALL RIGHTS RESERVED
Pinpoint
Test
TC
TC21 CHECK CONTINUITY OF MLP HARNESS

CIRCUITS
.~
Key off. Yes GO to ITCal.
Disconnect MLP sensor.
No ~ SERVICE open
Using a mirror, inspect both ends of the circuit(s). REMOVE
transmission harness connector at the MLP sensor breakout box.
Quick Test.
breakout box and MLP circuit at the MLP sensor
breakout box and SIG RTN circuit at the MLP
TC31 CHECK MLP CIRCUIT FOR SHORTS TO

POWER OR GROUND.
Key off. Yes ~ GO to ITC41.

Disconnect MLP sensor.
No ~ SERVICE short
Breakout box installed, processor disconnected. circuit(s). REMOVE
breakout box.
RECONNECT all
Pins 37 and 57 at the breakout box. Quick Test.

Pins 40, 46 and 60 at the breakout box and
between Test Pin 30 at the breakout box and
chassis ground.

ALL RIGHTS RESERVED
Pinpoint
Test
TC
TC4 I CHECK PROCESSOR OUTPUT VOLTAGE
Key off. Yes ~ GO to Transmission

MLP sensor disconnected. for MLP adjustment or
service.
No . REPLACE processor.
RECONNECT MLP
Key on, engine off. sensor. RERUN Quick
Test.
I
TC10 SERVICE CODE 47, 65, OR 97:
VERIFY VEHICLE SELF-TEST STATE
Service Code 47 indicates that the 4x4 Low selector Yes ~ For code 97:
lever is not in the 4x2 or 4x4 High position GO to ITC121.
(observed in Key On Engine Off Self-Test). An early
shift in 4x4 High range is likely. For all others:
GO to ITC111.
Service Code 65 indicates that Overdrive Cancel
Switch (OCS) is not cycled between the engine 1.0.
code and the " Goose Test" in Key On Engine
Running Self-Test. this time. For further
Service Code 97 indicates an Overdrive Cancel diagnosis using EEC-IV
monitor box, REFER to
Light circuit problem (observed in Key On Engine
Section 18 EEC-IV
Off Self-Test). Monitor Box:
Possible causes are: Intermittent Fault
Diagnosis.
- Faulty 4x4 Low switch
All others CLEAR
- Faulty OCS switch
Continuous Memory
- Burned out bulb (Refer to Quick Test
Appendix). RERUN
- Open harness Quick Test.
- Shorted harness
- Faulty processor
Rerun Quick Test.
Are any of the above codes present?

ALL RIGHTS RESERVED
Pinpoint
Test
TC
TC111 CYCLE THE APPROPRIATE CIRCUIT:

(4x4 LOW OR OVERDRIVE CANCEL)

Disconnect processor 60 pin connector. Inspect RERUN Quick Test.
for damaged or pushed out pins, loose wires, etc.
No ~ If you were here
Install breakout box, leave processor disconnected. originally for a
driveability symptom
Key on, engine off. only:
DVOM on 20 volt scale. GO to.ITC141.
For 4x4 LOW circuit: For All others:

GO to ITC121.
- Measure voltage between Test Pin 12 and Test
Pin 40 and 60 at the breakout box while
moving the 4x4 select lever between 4x2 and
4x4 Low several times.
- Move transfer case lever between 4x2 position
several times.
For OSC circuit:
- Measure voltage between Test Pin 41 and Test
Pin 40 and 60 at the breakout box while cycling
the overdrive cancel switch.
- Move the switch toggle on the dash several
times.

ALL RIGHTS RESERVED
. Pinpoint
Test"
TC
TEST STEP RESULT ~ , ACTION TO TAKE
TC121 CHECK HARNESS CIRCUIT(S) FOR SHORT TO

GROUND
Key off. Yes ~ For original code 47

or 65:
Breakout box installed, processor disconnected. GO to ITC1SI.
For ori~inal FOde 97:
For 4x4 LOW circuit: GO to TC13 .
- .Disconnect 4x4 low switch.
No ~ For original code 47:
- Measure resistance between Test Pin 12 and SERVICE short circuit.
Test Pin 40/60 at the breakout box. RERUN Engine Off
Self-Test.
For overdrive cancel circuits:
- Disconnect overdrive cancel switch. For original code 65:
SERVICE short circuit.
- Measure resistance between Test Pin 41 and RERUN Engine
Test Pin 40/60 at the breakout box. Running Self-Test. If
code is still present,
GO to ITC141.
Test Pin 40/60 at the breakout box.
Is each resistance greater than 10,000 ohms? For original cod~ 97:
SERVICE short circuit.

RERUN Engine Off
Self-Test.
TC131 CHECK KEYPOWER THROUGH OCll CIRCUIT
Key on, engine off. ,~ Yes ~ REPLACE processor.

Breakout box installed, processor disconnected. ,-
RERUN Quick Test.
No ~ GO to ITC141.
Pin 40/60 at breakout box.

ALL RIGHTS RESERVED
Pinpoint
Test
TC
TC14 CHECK CONTINUITY OF THE VEHICLE

HARNESS CIRCUITS
NOTE: When entering this Test Step with a Yes ~ GO to ITC1SI.

driveability symptom or a clean Self-Test
code; first, disconnect processor 60 pin No ~ Inspect for damaged
connector. Inspect for damaged pins, indicator bulb (4x4 low
pushed out pins, loose wires, etc. Service lED or OCll) or
as necessary. damaged fuse in fuse
panel. If OK, SERVICE
Key off. open circuit. REMOVE
Breakout box installed, processor disconnected. breakout box.
RECONNECT all
Appropriate switch disconnected. components. RERUN
Quick Test.
For 4x4 LOW circuit:
Measure the resistance between keypower at
the fuse panel shown below (ohmmeter positive
probe) and Test Pin 12 at the breakout box
(ohmmeter negative probe).
For OCIL circuit:
Measure the resistance between keypower at
the fuse panel shown below (ohmmeter positive
probe) and Test Pin 32 at the breakout box
(ohmmeter negative probe).
Are both resistances less than 5 ohms?

ALL RIGHTS RESERVED
EECIV Pinpoint Test Procedures - 17427
Pinpoint
Test
TC
TC15 CHECK CONTINUITY OF THE 4X4 LOW OR

OVERDRIVE CANCEL SWITCH HARNESS
Key off. . Yes ~ Go to ITC161 .

Breakout box connected, processor disconnected.
No SERVICE open
Appropriate switch disconnected. circuit(s). REMOVE
breakout box.
For 4x4 LOW circuit: components. RERUN
Quick Test.
the breakout box and 4x4 low circuit at the 4x4
low switch vehicle harness connector.
TEST PIN 12 o-4x4 LOW
TO INDICATOR LAMP .....---~~~~
4 x 4 LOW SWITCH VEHICLE

HARNESS CONNECTOR A12825-A
For OCS circuit:

Measure the resistance between keypower at the
fuse panel shown in Pinpoint Test Step ITC141
(ohmmeter positive probe) and the power side of
the overdrive cancel switch vehicle harness
connector (ohmmeter negative probe).
the breakout box and the signal side of the
overdrive cancel switch vehicle harness connector.
KEYPWR
AT OCIL32
FUSE
PANEL
CIRCUIT OCll
OVERDRIVE
CANCEL _
SWITCH A12830-A
Are both the resistances less than 5 ohms?

ALL RIGHTS RESERVED
17-428 . EEC-IV Pinpoint Test Procedures
Pinpoint
Test
TC
TC161 CHECK HARNESS CIRCUIT(S) FOR SHORTS

TO POWER
Key off. Yes ~ REPLACE damaged

switch, either 4x4L
Breakout box installed, processor disconnected. range switch or
overdrive cancel switch
Appropriate switch disconnected.
(OCS) due to service
DVOM on 200,000 ohm scale. code received.
For 4x4 LOW circuit: RECONNECT
- Measure resistance between Test Pin 12 and processor. RERUN
Test Pin 37 and 57 at the breakout box. Quick Test.
For overdrive cancel circuits: No ~ SERVICE short

- Measure resistance between Test Pin 41 and circuit(s). REMOVE
Test Pins 37 and 57 at the breakout box. breakout box.
RECONNECT all
- Measure resistance between Test Pin 32 and components. RERUN
Test Pins 37 and 57 at the breakout box. Quick Test.

ALL RIGHTS RESERVED
Pinpoint
Test
TC
TC171 SERVICE CODE 91, 92, 93, 94, 98, or 99:

CIRCUIT IDENTIFICATION
Service Code(s) 91, 92, 93, 94 indicates that the Yes ~ For 7.3L Diesel E40D:
appropriate On/Off solenoid below is out of Self- GO to ITC201.
Test'range which may induce harsh, early, or late
shifts. Correct range measurement is 9.00 to 14.50 For all other E40D:
volts when On, anq less than 1.00 volt when Off. "GO to ITC1SI.
Service Code 98 "indicates that the Electronic
Pressure Control solenoid may have an inoperative No ~ GO to Quick Test for
driver in the processor. Service Code 99 indicates appropriate direction on
that the EPC circuit problem may induce any other codes.
transmission clutch wear and harsh shifts.
- Solenoid resistance is out of limits
- Open or grounded harness
- Faulty processor
Verify code match per following chart:
Processor K.O.E.O.
Solenoid Signal Self-Test
Test Pin Code
SS1 52 91
SS2 19 92
CCS 55 93
CC9 53 94
EPC 38 98/99
SS1 - Shift Solenoid #" 1
SS2 - Shift Solenoid #" 2
CCS - Coast Clutch Solenoid
CCC - Converter Clutch Solenoid
EPC - Electronic Pressure Control
" Are any of the above codes present?

ALL RIGHTS RESERVED
Pinpoint
Test
TC
TC181 ENTER OUTPUT STATE CHECK (REFER TO

NOTE: DO NOT perform Output State Check on Yes ~ REMAIN in Output

7.3L DleselE40D vehicles because State Check. GO to
damage to transmission and vehicle may ITC191.
occur. This check is for 4.9L, 5.8L/7.5L
E40D VEHICLES ONLY. Do not use STAR
tester for this step, use VOM/DVOM.
No ~ DEPRESS throttle to
WOT and Release. If
Key off, wait 10 seconds. STO voltage does not
go high, GO to
Disconnect electrical connector on the speed . Pinpoint Test Step
control servo; if equipped. IQC11. Leave
DVOM on 20 volt scale. equipment hooked up.
Connect DVOM negative test lead to STO circuit
at Self-Test connector and positive test lead to
battery positive.
Jumper STI circuit to SIGNAL RETURN at the
Self-Test connector.
DVOM will indicate less than 1.0 volt when test is
completed.
Does voltage Increase?
TC191 CHECK SUSPECT E40D SOLENOID

ELECTRICAL OPERATION
Key on, engine off. Yes ~ GO to Transmission

Disconnect transmission bulkhead connector at
E40D transmission
E40D solenoids.
service.
Using a mirror, inspect both ends of the .
connector for damaged or pushed out pins,
corrosion, loose wires, ect. Service as necessary.
No ~ REMOVE jumper. GO
to ITC201.
Connect DVOM positive test lead to VPWR circuit
and negative test lead to the processor signal test
pin (refer to table in ITC171) at the E40D .
While observing DVOM, depress and release the
throttle several times to cycle output On and Off.
Does the suspect solenoid output circuit
'voltage change greater than 1.0 volt?

ALL RIGHTS RESERVED
ITransmission - E40D -
.Pinpoint
Test
TC
I
TC20 CHECK E40D TRANSMISSION SOLENOID
RESISTANCE
Key off, wait 10 seconds. Yes ~ GO to ITC22 I ~

Disconnect processor 60 'pin connector. Inspect
for damaged or pushed out pins, corrosion, loose No ~ GO to ITC211.
Connect transmission bulkhead connector.
Measure the resistance between Test Pin 37/57
jnd processor signal test pin (refer to table in
TC17 ) at the breakout box.
Is the resistance within specification per the
chart below?
Ambient Resistance
. Temperature (OHMS)
C of Solenoid MIN MAX .
55. eee, 16.00 20.50
- 40 - 40 ees
to 0 to 32
EPe 3.25 4.25
55. eee,
o to 32 to ess 20.50 30.00
110 230
EPe 4.25 6.50

ALL RIGHTS RESERVED
Pinpoint
Test
TC
I
TC21 CHECK CONTINUITY OF E40D TRANSMISSION
SOLENOID HARNESS
NOTE: When entering this pinpoint test for a Yes ~ GO to ITC221.

7.3L Diesel, initially use a mirror to
inspect both ends of the transmission No ~ SERVICE open circuit.
bulkhead connector for damaged or REMOVE breakout box.
pushed out pins, corrosion, loose wires, RECONNECT all
ect. Service as necessary. components. RERUN
Quick Test.
Disconnect transmission bulkhead connector at
E40D solenoids.
signal test pin (refer to table in ITC171) at the
breakout box and the same test pin at the E40D
Measure the resistance between Test Pin 37/57
(Test Pin 35 for 7.3L Diesel) at the breakout box
and both the EPCPWR. pin and the VPWR pin at
the E40D transmission vehicle bulkhead harness
connector. (Refer to the first Pinpoint Test
Schematic in ITC I).
TC221 CHECK E40D SOLENOID HARNESS CIRCUITS

FOR SHORTS TO GROUND
Key off, wait 10 seconds. Yes ~ GO to ITC231.

No ~ SERVICE short
Transmission bulkhead connector disconnected. circuit(s). REMOVE
breakout box.
RECONNECT all
Measure the resistance between the processor components. RERUN
signal test pin (refer to table in ITC171) and Test Quick Test.
Pins 40, 46 and 60 at the breakout box and
between the processor signal test pin at the

ALL RIGHTS RESERVED
Pinpoint
ITransmission - E40D Test'
TC
I
TC23 CHECK E40D SOLENOID HARNESS CIRCUITS
FOR SHORTS TO POWER .
.Key off, wait 10 seconds. Yes ~ GO to ITC241.

No ~ SERVICE short
Transmission bulkhead connector disconnected. circuit(s). REMOVE
breakout box.
Measure the resistance between the processor components. RERUN
signal test pin (refer to table in ITC171) and Test Quick Test.
..
I
TC24 CHECK VOLTAGE OF VPWR TO E40D
TRANSMISSION SOLENOIDS
Key off. Yes ~ GO to ITC25\.

Connect processor to breakout box. REMOVE breakout box.
RECONNECT all
Transmission bulkhead connector disconnected. components. RERUN
Key on, engine off.

Measure voltage between VPWR circuits (Test
Pins 37 and 57) at the E40D transmission vehicle
harness connector and chassis ground or negative
battery post.
Are both voltages greater than 10.5 volts?
"

ALL RIGHTS RESERVED
Pinpoint
Test
TC
TC25 CHECK SOLENOID DRIVER SIGNAL
Requires standard non-power 12 volt lamp. Yes ~ GO to Transmission

Key off. for E40D transmission
Breakout box installed, processor connected. service.
Bulkhead connector disconnected.
Connect test lamp between Test Pin 37 or 57
No ~ If test lamp never
flashed:
jnd processor signal test pin (refer to table in Solenoid Driver open in
TC17 ) at the breakout box. processor. REPLACE
Key on, engine off (wait 10 seconds). processor. REMOVE
breakout box.
NOTE: For Pins 38 (EPC) and 52 (SS1), the lamp RECONNECT all
will be "ON" with key On, ignore this; components. RERUN
only concern is the light during Self-Test. . Quick Test.
Now initiate Key On Engine Off Self-Test.
If test lamp is always
Does test lamp flash momentarily when Self on:
Test is initiated and then stay off? Solenoid Driver shorted
to ground in processor.
REPLACE processor.
RECONNECT all
components. RERUN
Quick Test.
TC30 SERVICE CODE 26: .

CHECK TRANSMISSION OIL OPERATING
TEMPERATURE
Service Code 26 indicates that the Transmission Oil Yes ~ GO to ITC311.

Temperature (TOT) sensor is out of Self-Test range.
Correct range of measurement is 0.21 to 3.50 volts. No ~ SERVICE other codes
as necessary.
- TOT resistance is out of limits
- Faulty processor
Drive vehicle through normal shift cycle in city
traffic for 20 to 30 minutes to bring transmission
oil temperature to at least 50 degrees Fahrenheit.
If outside ambient temperature is less than -2
degrees Fahrenheit the vehicle may require a
longer drive warm-up time.
Rerun Quick Test.
Is code 26 present?

ALL RIGHTS RESERVED
Pinpoint
ITransmission - E40D Test
TC
I
TC31 CHECK FOR VREF AT THROTTLE POSITION
OR FIPL SENSOR
-
Refer to schematic in Pinpoint Test IDH I or IDO I. Yes ~ RECONNECT TP or

FIPL sensor. GO to
Key off, wait 10 seconds. ITC321.
wires, etc. Service as necessary. Step IC11.
breakout box.
Disconnect TP sensor (FIPL sensor on 7.3L
Diesel).
Key on, engine off.
Measure voltage between VREF and SIG RTN
circuits at the TP or FIPL sensor vehicle harness'
connector.
Is Yoltage between 4.0 and 6.0 YOIts?

ALL RIGHTS RESERVED
I"----~
~iSSion-E40D ~TPes~tint
_ _I. ~~_ .~C~
I
TC32 CHECK RESISTANCE OF TOT SENSOR
NOTE: Transmission oil temperature may have Yes ~ GO to ITC331.

cooled down. The oil temperature must
be at a minimum of 50 degrees No ~ REMOVE breakout box.
Fahrenheit before taking TOT resistance RECONNNECT all
measurement. Redrive vehicle if components. GO to
necessary. Transmission Shop
Key off, wait 10 seconds. Manual Group for
Breakout box installed. transmission service of
Disconnect processor. the TOT sensor.
Key on, engine off.
Carefully touch the transmission oil pan on the
driver's side, away from the exhaust system. The
transmission oil pan should be warm to the touch.
As a guide, "warm to the touch" is about 41-70 0
degrees C (1 05-1 58 0 degrees F).
Measure the resistance between Test Pin 42 (Test
Pin 7 on 7.3L diesel) and Test Pin 46 at the
breakout box. Refer to TOT Sensor Resistance
Specification Table # 2.
Is the resistance within specification for the
appropriate transmission oil temperature?
Transmission Oil Temperature (TOT) Sensor

Resistance Specification Table # 2
Transmission Oil Resistance

Temperature Range
(ohms)
o - 20 32 - 58 100K 37K
21 40 59 - 104 37K - 16K
41 - 70 105 - 158 16K - 5K
71 90 159 - 194 5K - 2.7K
91 110 195 - 230 2.7K - 1.5K
111 - 130 231 - 266 1.5K 0.8K

ALL RIGHTS RESERVED
EEC-IV Pinpoi,nt Test Procedures 17-437
Pinpoint
Test
TC
I
TC33 CHECK TOT SENSOR RESISTANCE SHIFT VS
OIL TEMPERATURE SHIFT
NOTE: The TOT sensor may sometimes appear Yes ~ REPLACE processor.
to be within the appropriate resistance REMOVE breakout box.
specification (O.8K to 100K ohms) and not RERUN Quick Test.
be in the corresponding temperature
range. This increases the chances of not No ~ REMOVE breakout box.
being able to determine the integrity of RECONNECT
the TOT sensor. processor. GO to
Transmission Shop
Check again for the transmission temperature by Manual Group for TOT
touching the transmission oil pan. sensor replacement"
procedures.
- If it is cold, run the vehicle for a short time
to heat it up.
- ' If it is too hot to touch, let the vehicle and
transmission cool down.
Measure the TOT sensor resistance again and
compare it to the resistance received in Pinpoint , "
Test Step ITC32 I.

Did the resistance decrease upon heating the
transmission or increase upon cooling down
the transmission significantly? ,
I
TC40 SERVICE CODE 56:
-
Service Code 56 indicates that the Transmission Oil Yes ~ REMOVE jumper wire.
Temperature (TOT) sensor signal is greater than GO to Transmission
Self~Test maximum. value of 4.80 volts. Shop Manual Group for
transmission service of
Possible causes are: the TOT sensor.
- Faulty TOT sensor
- Open harness
No ~ REM01E iUiper wire.
GO to TC41 .
- Faulty processor
Disconnect transm"ission bulkhead connector at
TOT sensor. Inspect for damaged or pushed out
necessary.
Insert a jumper wire between TOT circuit and SIG
RTN circuit at the E40D transmission vehicle
harness connector.
Run Key On Engine Off Self~Test.
Is code 66 present?

ALL RIGHTS RESERVED
117.438 EECIV Pinpoint Test Procedures
Pinpoint
Test
TC
I
TC41 CHECK CONTINUITY OF TOT AND SIG RTN
CIRCUITS
Key off,wait 10 seconds. Yes ~ REPLACE processor.

Transmission bulkhead connector disconnected. RECONNECT all
Quick Test.
No ~ SERVICE open
Install breakout box, leave processor disconnected. circuit(s). REMOVE
DVOM on 200 ohm scale. breakout box.
RECONNECT all
Measure the resistance between TOT circuit at components. RERUN
the E40D transmission vehicle harness connector Quick Test.
and Test Pin 42 (or Test Pin 7 on 7.3L diesel) at
the breakout box.
Measure the resistance between SIG RTN circuit
at the E40D transmission vehicle harness
connector and Test Pin 46 at the breakout box.
Are both resistances less the 5 ohms?
I
TC50 SERVICE CODE 66: .
Service Code 66 indicates that the Transmission Oil Yes ~ GO to Transmission

Temperature (TOn sensor signal is less than the Shop Manual Group for
Self-Test minimum value of 0.15 volts. transmission service of
the TOT sensor.
- Faulty TOT sensor No ~ GO to ITC511.
- Grounded harness
- Faulty processor
Disconnect transmission bulkhead connector at the
TOT sensor. Inspect for damaged or pushed out
necessary.
Is code 56 present?
(

ALL RIGHTS RESERVED
EEC-IV Pinpoint Test Procedures 17-439/, "
Pinpoint
Test
TC
.
I
TC51 CHECK FOR VREF AT THROTTLE POSITION
SENSOR
Refer to schematic in Pinpoint Test IDH I or 10QI. Yes ~ . RECONNECT TP or

FIPL sensor. GO to
Key off, wait 10 seconds. ITC521.
wires, etc. Service as necessary. Step IC11.
breakout box.
Disconnect TP sensor (FIPL sensor on 7.3L
diesel).
Key on, engine off.
Measure voltage between VREF and SIG RTN
circuits at the TP or FIPL sensor vehicle harness
connector.
I
TC52 CHECK TOT CIRCUIT FOR SHORTS TO
GROUND

Transmission bulkhead connector disconnected. RECONNECT all
Breakout box installed. components. RERUN
Quick Test.
DVOM on 200,000 ohm scale No ~ SERVICE short circuit.
Measure the resistance between Test Pin 42 (or RECONNECT all
Test Pin 7 on 7.3L diesel) and Test Pins 40, 46 components. RERUN
and 60 at the breakout box. Quick Test.

ALL RIGHTS RESERVED
I,,--T_r_a_D_sm
. . . . _i_SS_i_O_D_-_E_4_0_D 11 Pi;:::nt I'--_T_C_---'
,
I
TC90 MLP. TOT SENSOR AND E40D SOLENOID
DRIVE CYCLE
Verify that all components are connected.

Bring engine to operating temperature.
Verify correct transmission fluid level.
Run Key On Engine Off Self-Test and record
Continuous Memory Codes.
- If codes 49, 59 or 69 are present .................. ~

- GO to ITC961.
- If codes 49, 59 or 69 are not present. record

and clear Continuous Memory Self-Test
Codes.
With transmission in D range, and OD enable set:
- Drive in city traffic with moderate
accelerations.
- Hold throttle opening steady while
transmission is shifting thorugh all four gears.
then hold throttle for an additional 15
seconds.
Apply brakes on coming to a stop and remain
stopped for 20 seconds. then repeat drive step
above.
Rerun Key On Engine Off Self-Test and record
Continuous Memory Codes.
- For code 11 ............................................... .~ GO to ITC911.
- For code 29 ............................................... ~
po
GO to Pinpoint Test
IOP11.
- ~
For code 56. 62. 66, 67 and 99 .....................
- GO to ITC921.
TC91 I
ATIEMPT TO GENERATE CONTINUOUS
MEMORY CODE 56, 62, 66. 67 and 99
NOTE: Before performing any procedures in this Yes ~ RETURN vehicle to

test step you must complete the drive repair Iarea. GO to
cycle outlined above. [TC92 .
Take the vehicle on the road again and drive on
a rough road for 15 minutes to simulate road No ~ Unable to duplicate
shock. fault. Testing is
completed.
Observe MIL LED while driving for indication of
fault.
Does the MIL flash on and off?

ALL RIGHTS RESERVED
I.Transmi~Sion-E40D Pinpoint
Test
-TC
TEST STEP 'RESULT ~ ACTION TO TAKE
I
TC92 CHECK CIRCUIT USING KEY ON ENGINE OFF
CONTINUOUS MONITOR MODE
Enter Key On Engine Off Continuous Monitor Yes ~ DISCONNECT and

mode. Refer to Quick Test Appendix. INSPECT connectors. If
terminals are good, GO
Observe VOM or STAR LED for indication of a to Transmission Shop
fault while performing the following: Manual Group for MLP,
TOT sensor(s) or
For MLP sensor (code 67): E40D solenoid service
Lightly tap on MLP sensor (simulate road shock). CLEAR Continuous
Memory Code(s)
Wiggle connector at MLP sensor. (REFER to Quick Test
Appendix).
For E40D transmission solenoids (codes 62 or
99) and Transmission Oil Temperature (TOT) Continuous Memory
sensor (Codes 56 or 66): Code testing is
Wiggle transmission bulkhead connector. complete.
No ~ GO to Ilc931.
I
TC93 CHECK EEC'-IV VEHICLE HARNESS ;
Still in Key On Engine Off Continuous Monitor Yes ~ ISOLATE fault and
CLEAR Continuous
Observe VOM or STAR LED for a fault indication Memory Code(s)
while performing the following: (REFER to Quick Test
Appendix). RERUN
- Referring to the illustration in IlC94 I , grasp Quick Test.
the harness closest to the sensor/
transmission connector. Wiggle, shake or bend
a small section of the EEC-IV system vehicle No ~ GO to IlC9SI.
panel, processor, and transmission.
,
'.

ALL RIGHTS RESERVED
17442 EECMIV Pinpoint Test Procedures
Pinpoint
[Transmission -:- E40D TC
Test
TC94 SCHEMATIC FOR CONTINUOUS MONITOR MODE ON EEC-IV/E40D VEHICLE HARNESS
VREF
RV
-o---o.....-----t~>- MLP SIG~>-+--o--==--.....,
--.....0----+-_>-- EPC SIG-~--o--..,
II
----0.....-----+->-- EPC PWR-
(DIESEL ONLY)
---o---+-"-~ CCC SIG----"'>-+--o----,
1/
- - - 0 - -..........-) VPWRJEPC PWR.. >--+---0----

TOPWR~ TOGND,x I
fC f. ~~..->-1'*roTSIG~)>--+:-oo- .......
I I I
x-x SHORTS TO I
I
,
, I
GROUND OR POWER
X XOPENS
.1 -- -O--+~>w
~ SIG RTN_ >~II-O-""'---""
"
PROCESSOR HARNESS E40D SENSORS &SOLENOIDS ASSEMBLY A12831-A

ALL RIGHTS RESERVED
Pinpoint
Test
TC
TC9S1 CHECK PROCESSOR AND HARNESS

.. CONNECTORS

and/or identify. fault at
both connector terminals for damaged or pushed diagnosis using the
out pins, corrosion, loose wires, etc. Service as EEC-IV Monitor box,.
necessary, damage or faults. REFER to Section 18
EEC-IV Monitor Box:
Are connectors and terminals OK? Intermittent Fault
Diagnosis.
AI' others, CLEAR

Continuous Memory
Appendix). RERUN
Quick Test.
CLEAR Continuous
Memory Code(s)
Appendix). RERUN
Quick Test.
I
TC96 CONTINUOUS MEMORY CODES 49, 59, 69:
FAULT ISOLATION
Service Code(s) 49, 59, 69 indicates that the Yes ~ GO to Quick Test to
transmission went through four improper shifts in an service other codes.
upward or downward gear range (1-2 gear, 2-3 gear,
or 3-4 gear and in reverse direction) consecutively No ~ GO to ITC971.
over a period of drive time. When changing a gear
position either the SS1 or SS2 solenoid remained
On or Off an extended amount of time.
.
- Intermittent harness continuity
- MLP sensor out of adjustment
- Stuck shift solenoid
Do any other codes appear in Key On Engine
Off Self-Test in addition to the Continuous
Memory Codes 49, S9 or 69?

ALL RIGHTS RESERVED
?inpoint
Test
TC
I
TC97 CHECK CIRCUITS USING KEY ON ENGINE
OFF CONTINUOUS MONITOR MODE ~
Enter Key On Engine Off Continuous Monitor Yes ~ DISCONNECT and

mode. Refer to Quick Test Appendix. INSPECT connectors
and for loose wires.
Observe VOM or STAR LED for indication of a SERVICE as necessary.
fault while performing the following: CLEAR Continuous
Memory Code(s). Refer
- Wiggle, shake or bend a small section of the to Quick Test
EEC-IV system vehicle harness while working Appendix. Continuous
your way to the dash panel, processor, and Memory Code testing is
transmission bulkhead connector. completed.
No ~ GO to Transmission
E40D (S51 or 5S2)
transmission service.

ALL RIGHTS RESERVED
Pinpoint
IIntegrated Controller Test
x
INote I
You should enter this Pinpoint Test only when service code 72,78, 82, 83, 87, 88, 95
and 96 are received durJ!!.p Quick Test or if you have been directed here from Pinpoint
Test [A] " Pinpoint Test ~, or Diagnosis By Symptom.
IRemember I
may be at fault: . .
Fuel Lines
Fuel Filters
Contaminated Fuel
Fuel Pump
Ignition Switch
Battery Cables
Alternator
Voltage Regulator
Ground Straps
AIC Clutch
AIC Demand
Cooling Fan Motor
This Pinpoint Test is inte'nded to' diagnose oniy the following:
Integrated Relay Controller Module
Battery Voltage
Power Relay
EDF Relay
HEDF Relay
WAC Relay
Fuel Pump Relay
Harness circuits: VBAT, VPWR, F.P., GND and PWR to Fuel Pump(s), WAC, ACC, ACCS,
Cooling Fan Power, AIC Clutch, Key PWR, PWR to Integrated Controller
AIC Demand Switch Input

ALL RIGHTS RESERVED
Pinpoint
x

2.5L CFI CLC, 3.0L EFI AXOD and 3.0L Probe
TEST PIN 8~F~P~M:....- -,
INERTIA
SWITCH
POWER-
TO-
PUMP
TEST PIN 22 --=-F..:..P ~-------~ ~---------___mlo
FUEL
TEST PIN 37 _V:..:.P....:W.:.:R..:.--4I~_+- ~~ ...:.P..;:U:..:..:.M:.:...P...:.R..:.:E:.=L:..;.AY~_----.+...,
TEST PIN 57 VPWR

FOR 3.0L
PROBE ONLY
60 PIN
BATTERY
20 40 60
55 EDF
COOLING
HEDF FAN
52 HEDF RELAY
AlC
AlC OEM. CYCLIC
CLUTCH
SWITCH PRESSURE SWITCH
COIL
_ _' . .......-_-41~:.--.----------1 SOLID
10 ACCS STATE
54~W:.;.A~C:::..+ ~ ~ ...., RELAY
+
1 21 41
TIME DELAY DELETED FOR

3.lIL EFI AXOD
12 7 6 6 7 12
24 19 18 13 13 18 19 24
A9968D
Refer to Engine Supplement Section for Test Pin Usage Chart.

ALL RIGHTS RESERVED
IIntegrated Controller Pinpoint

Test
x
I Pinpoint Test Schematic 1

3.0L SEFI Super High Output (SHO)
TEST PIN 19 _F....;.P...;.;,M.:....... ---,
1.1[\
IDLE FUEL PUMP RELAY
TEST PIN 22 --..;.F.;.,P -+ ---:lI )-..:.::.... +.I'IIrftII''4----J

INERTIA
SWITCH
TEST PIN 41 _F_P -+ ---4I ~------_+_--_4'mlU'_I____.

HIGH FUEL
TEST PIN 37 _V.:....;P....;,W..:..;R...:..-......__-I_-------~...=...:..------~--:...FU.;:;,;E=L:..,..;....PU=-M....;.P-R....;.E=LA:~~....____. PUMP
TEST PIN 57 VPWR
60 PIN
BATIERY
20 4060
55EDF
COOLING
FAN
NC
NCDEM 12 CLUTCH
SWITCH COIL
~'....~_.. ~.-.....---,-~'\..=..21:.....---------~SOLID
10 ACCS ---------- STATE
54"W.AC -+-------~----' ~2:.;:2:.......- ~ RELAY +
1 21 41
24 19
A9259-B
Refer to Engine Supplement ?ection for Test Pin Usage Chart.

ALL RIGHTS RESERVED
Pinpoint
x
I Pinpoint Test Schematic I

3.8L SEFI AXOD
5FPM
0--------------------------------------------,
FUEL
PUMP
22 FP
FUEL
PUMP RELAY
VPWR
37 - - - -.....~----------~r'---------+-:E""'E"'"C---------1.----,
57 VPWR POWER RELAY
60 PIN
BATIERY
20 40 60
LOW
SPEED
VBAT
55 EOF
HI
SPEED
COOLING " ' - - - - - - - - - 4

FAN
AlC OEM AIC

SWITCH CLUTCH
COIL
10 ACCS
54 WAC
1 21 41

A13612-A

ALL RIGHTS RESERVED
Pinpoint
x

3.8L SEFI SUPERCHARGER
37 VPWR 24
57 VPWR
IGNITION
SWITCH
BATTERY START/RUN
6O-PIN
20 40 60
VBAT
55 .:;ED:;;.;F_-+-----;I-- ~-------__..:jf).:::--___::....Wl
41 HEDF
AlC DEM.
SWITCH
ACCS
. -.. . . . . . .--_--...~~_~f~~----------_1 SOLID 1-- . -_ _....:;2.::..3-<1f_ _"""'\
~WAC
STATE
1 21 41 22 RELAY +
AlC
15 CLUTCH
COIL
16
NOTE: FUEL PUMP RELAY LOCATED IN REAR OF VEHICLE.

A12790-B

ALL RIGHTS RESERVED

Test
x
X1 I CHECK BATIERY VOLTAGE
Key on, engine off. Yes ~ GO ~o IX21.

No ~ SERVICE discharged
Measure voltage across battery terminals. battery, REFER to
Is voltage greater than 10.5 volts? Charging/ Electrical
Group in Shop Manual.
X2 I CHECK BATIERY GROUND
Key on, engine off. Yes ~ GO to IX31.

No ~ GO to IX61.
and SIG RTN circuit in the Self-Test connector.
X3 I GROUND FAULT ISOLATION
Key off. Yes ~ GO to IX4!.

for damaged or pushed out pins, corrosion, loose No ~ SERVICE open ground
wires etc. Service as necessary. circuit. REMOVE
breakout box.
Install breakout box and connect processor to RECONNECT
breakout box. processor. RERUN
Key on, engine off.

and Test Pins 40 and 60 at the breakout box.
Is each voltage less than 0.5 volts?
X4 I PROCESSOR GROUND FAULT

ISOLATION
Key off, wait 10 seconds. Yes ~ GO to Ixsl.

Measure resistance between Test Pin 46 and Test RERUN Quick Test.

ALL RIGHTS RESERVED
Pinpoint
x
XS I CHECK SIG RTN CIRCUIT CONTINUITY
Key off, ,wait 10 seconds. Yes ~ System OK. REMOVE

" . breakout box.
.
RECONNECT
processor. RERUN
Quick Test.
breakout box and SIG RTN circuit at Self-Test
connector.
No ~ SERVICE ope~ circuit.
" REMOVE breakout box.
Is resistance less than 5.0 ohms? RECONNECT
processor. RERUN
- Quick Test.
I
I
X6 MEASURE VOLTAGE AND GROUND TO

INTEGRATED CONTROLLER
Key off. Yes ,~ GO to IX71.

Disconnect Integrated Controller.
No ~ GO to IX91.
Measure voltage between pin 8 and pin 15 at the
Integrated Controller vehicle harness connector.
Is Yoltage, greater than 10.5 Yolts?
,X7 ICHECK KEY POWER TO INTEGRATED

CONTROLLER , .
Key" off.' , . Yes ~ GO to Ixsl.

Integrated' Controller disconnected.
No ~ SERVICE open
DVOM. on 20 volt s~ale. between Pin 13 and
ignition switch.
Key' on, engine off. RECONNECT
Measure voltage between Pin 13 and Pin 15 at Integrated Controller.
the Integrated Controller vehicle harness RERUN Quick Test.
connector.

ALL RIGHTS RESERVED
Pinpoint
x
X8 I CHECK VPWR CIRCUIT CONTINUITY
Key off. Yes ~ SERVICE open in

VPWR circuit. REMOVE
Integrated Controller disconnected. breakout box.
components. RERUN
. for damaged or pushed out pins, corrosion, loose
Quick Test.
Install breakout box, leave processor disconnected. No ~ REPLACE Integrated
DVOM on 200 ohm scale. Controller. REMOVE
breakout box.
Measure resistance between Test Pins 37 and 57 RECONNECT
at the breakout box and Pin 24 at the Integrated processor. RE.RUN
Controller vehicle harness connector. Quick Test.
Is resistance greater than 5.0 ohms?
X9 I MEASURE CONTINUITY OF POWER GROUND

TO INTEGRATED CONTROLLER

battery ground to Pin
Integrated Controller disconnected. 15 (Integrated
DVOM on 200 ohm scale. Contrqller harness
connector).
Measure resistance between battery negative post RECONNECT
and Pin 15 at the Integrated Controller vehicle Integrated Controller.
harness connector. RERUN Quick Test.
Is resistance greater than 5.0 ohms?

battery positive to Pin
8 (Integrated Controller
harness connector).
RECONNECT
Integrated Controller.
RERUN Quick Test.

ALL RIGHTS RESERVED
EEC-IV'Plnpoint Test Procedures 17-453

Test
x
X10 SERVICE CODE 72:

CHECK VPWR CIRCUIT FOR INTERMITTENT
OPEN .
Service Code 72 indicates that while Key Power Yes ~ CHECK for proper
was present, VPWR was interrupted or interference routing of EEC
from electrical noises caused the processor to reset, harness. SERVICE as
resulting in possible s~alls, high idle rpm, lack of necessary. If OK
SERVICE intermittent
power on acceleration or other drive symptoms.
VPWR circuit. RERUN.
Possible Causes: Quick Test. .
- Intermittent open in VpWR circuit from '.

integrated controller to processor. No INSPECT component
and harness
- EEC power relay intermitten.t malfunction. ; connectors of
Integrated Controller
- Intermittent open in VBAT circuit to integrated and processor, for
controller. loose or damaged pins,
- Intermittent open in KEY POWER circuit to corrosion, .etc.
integrated controller. -
If OK, .ROAD TEST
- EEC harness too close to the distributor spark vehicle through. a
plug wires a~d other vehicle harnesses. variety of drive modes.
If symptom exists,
Enter Continuous. Monitor Mode (Engine Running) REPLACE Integrated
per Quick Test Appendix. Observe YOM or STAR Controller, otherwise
LED for indication of a fault while performing the testing complete.
following: RERUN Quick Test.
Shake,' bend and twist vehicle harness from
Integrated Controller to the processor, to the
ignition switch
~ . .. and . to battery positive post.
.~
Is a fault indicated. or does Code 72 reappear

in Continuous Memory 'if .Quick Test is rerun?
X11 CHECK POWER-TO-PUMP(S) CIRCUIT

VOLTAGE .
Key on, engine off. Yes ~ GO to Fuel/Engine

Shop Manual Group,
Locate 'and disconnect fuel pump(s). Electric Fuel Pump
. DVOM on 20 volt scale.'. Diagnosis.
Measure voltage between CHASSIS GROUND and

No ~ GO to IX121.
POWER-TO-PUMP(s) circuit at the fuel pump
vehicle harness connect<?r during crank mode.
... Is Yoltage greater than 8.0 Yolts during. crank?

ALL RIGHTS RESERVED
IIntegrated Co~troller Pinpoint

Test
x
X121 CHECK POWER-TO-PUMP(S) CIRCUIT

CONTINUITY
Key off. Yes ~ REPLACE Integrated

Controller.
Disconnect Integrated Controller. RECONNECT all
components. 'RERUN
Fuel pump(s) disconnected.
Quick Test.
Measure resistance between Pin 5 at the No ~ SERVICE open in
Integrated Controller vehicle harness connector POWER-TO~PUMP(s)
and POWER-TO-PUMP(s) circuit at the fuel pump circuit. RECONNECT all

components. RERUN
. QuicK Test.
X141 CHECK POWER-TO-PUMP(S) CIRCUIT FOR

SHORTS TO POWER
Key off. Yes ~ REPLACE'lntegrated

Controller.
Disconnect Integrated Cqntroller. RECONNECT fuel
pump. RERUN Quick
Disc~nnect fuel pump(s).
Test.
Measure resistance between Pin 5 and Pin 24 at No ~ SERVICE short circuit.
the Integrated Controller vehicle harness RECONNECT all
connector. components. ATTEMPT
to start vehicle. If
Measure resistance between Pin 5 at the vehicle runs, RERUN
Integrated Controller vehicle harness connector Quick Test. If vehicle
and battery positive post. will not run, REPLACE
Is each resistance greater than 10,000 ohms? RERUN Quick Test.

ALL RIGHTS RESERVED

Test
x
. , TEST STEP RESULT ~ ACTION TO TAKE
X151 SERVICE CODE 87/83: "

CHECK CONTINUITY OF FUEL PUMP CIRCUIT
,Service Code 87 or 83 indicates that the voltage Yes ~ GO to IX161.

output for the high or low fuel pump circuit did not
change when activated during Key On Engine Off No ~ SERVICE open in fuel
Self-Test. pump circuit. REMOVE
breakout box.
RECONNECT all
- Open or grounded fuel pump circuit. components. RERUN
Quick Test.
- Open or grounded processor output driver.
Key off.
.
for damaged or pushed out pins, corrosion, loose ,
For Service Code 87 (except 3.0L SHO):
breakout box and Pin 18 at the Integrated
Controller vehicle harness connector. "
For Service Code 87 (3.0L SHO):

Measure resistance between Test Pin 41 at -the -
breakout box and Pin 11, at the Integrated
Controller vehicle harness connector.
,For Service Code 83 (3.0L SHO):
..
breakout box and' 'Pin 18 at the Integrated . '

Is resis~ance I,ess than 5.0 ohms?

ALL RIGHTS RESERVED
Pinpoint
x
X161 CHECK APPROPRIATE FUEL PUMP CIRCUIT

FOR SHORTS TO POWER AND GROUND
Key off. Yes ~ GO to IX171.

No ~ SERVICE the
Integrated Controller disconnected. appropriate fuel pump
circuit shorts to power
DVOM on 200,.000 ohm scale. or groLind. REMOVE
For Service Code 87 (except 3.0L SHO): breakout box.
RECONNECT all
Pins 37, 57 and battery positive post and between Quick Test. If code 87
Test Pin 22 and Test Pins 40, 60 and battery or 83 is still present,
negative post. GO to IX171.
Pins 37, 57 and battery positive post and between
Test Pin 41 and Test Pins 40, 60 and battery
negative post.
X17 I CHECK FUEL PUMP RELAY COIL RESISTANCE
Key off. Yes ~ F~EPLACE processor.

HEMOVE breakout box.
.. Breakout box installed, processor disconnected. F~ECONNECT
Integrated Controller disconnected. Integrated Controller.
F~ERUN Quick Test.
Measure resistance of Integrated Controller from No ~ REPLACE Integrated
Pin 18 to 24 or from Pin 11 to 24 as appropriate. Controller. REMOVE
breakout box.
Is resistance between 65 and 100 ohms? RECONNECT
processor. RERUN
Ouick Test.

ALL RIGHTS RESERVED
IIntegrated Con~roller Pinpoint

Test
x
X18 NO HIGH OR LOW FAN
Key off.. Yes ~ GO to IX191.

battery power circuit. .
Key on, engine off. . RECONNECT
Measure voltage between battery negative post Integrated. Controller.
and Pins 1, 2, 6 and 7, (for 3.8L, Pins 3 and 4) RE-EVALUATE
respectively at the Integrated Controller vehicle symptom.
harness connector.
Is each Yoltage greater than 10.5 YOIts?
X19 CHECK FAN MOTOR OPERATION
Key off. Yes ~ For 3.8L:

Integrated Controller disconnected. GO to IX201.
Jumper Pin 3 to Pin 6 at Integrated Controller For all others:

vehicle harness connector. GO to IX2SI ..
Does fan run?
~
No
. GO to IX211.

..
Key off. Yes ~ GO to IX2SI.
Integrated Controller disconnected.
Jumper Pin 3 to Pin 2 at Integrated Controller
No ~ GO to .. IX231.
. Does fan run?
X21 MEASURE BATTERY VOLTAGE SUPPLY AT

FAN - BYPASSING INTEGRATED
CONTROLLER
Key off. Yes ~ REPLACE fan motor.

RECONNECT
Disconnect cooling fan.
Integrated Controller disconnected. RE-EVALUATE
Jumper Pin 3 to Pin 6 at Integrated Controller symptom.
DVOM on 20 volt scale. No ~ GO to IX221.
Measure voltage at cooling fan vehicle harness
connector.

ALL RIGHTS RESERVED
Pinpoint
!Integrated Controller
Test
x
TEST. STEP RESULT ~ ACTION TO TAKE
X22 I VERIFY COOLING FAN GROUND

ground circuit to fan.
Integrated Controller disconnected. components.
RE-EVALUATE
DVOM on 20 volt scale. No ~ SERVICE open in
power-to-fan circuit
Measure voltage between voltage positive at from Pin 3 and Pin 4
cooling fan vehicles harness connector and (for 3.8L, Pin 6 and
battery negative post. Pin 7) of Integrated
Controller vehicle
Is Yoltage greater than 8.0 Yolts? harness connector to
cooling fan vehicle
harness connector.
RECONNECT all
components.
RE-EVALUATE
symptom.
X23 I MEASURE BATTERY VOLTAGE SUPPLY AT

FAN-BYPASSING INTEGRATED CONTROLLER
Key off. Yes ~ REPLACE fan motor.

RECONNECT
Disconnect cooling fan. Integrated Controller.
symptom.
vehicle harness connector. No ~ GO to IX241.
connector.
Is yoltage greater than 8.0 YO Its?

ALL RIGHTS RESERVED

Test
x

RE-EVALUATE
Jumper Pin 3 to Pin 2 at Integrated Controller symptom..
DVOM on 20 volt scale. No .~ SERVICE open in
cooling fan vehicle harness connector and battery of Integrated Controller
negative post. vehicle harness
connector to cooling
Is Yoltage greater than 8.0 Yolts? fan vehicle harness
connector.
RECONN.ECT all
components.
RE-EVALUATE
symptom.
X25 I CHECK FAN RUNNING MODE (LOW)

No ~ REPLACE Integrated
Reconnect Integrated Controller. Controller.
RECONNECT
Key on, engine off. processor
Does fan run at low speed? RE-EVALUATE
symptom.

ALL RIGHTS RESERVED
Pinpoint
x
X261 JUMPER HIGH ELECTRIC-DRIVE SIGNAL

(HEDF) TO GROUND
Key off. Yes ~ GO to \X271.
Inspect processor 60 pin connector for damaged

or pushed out pins, corrosion, loose wires, etc. No ~ . REPLACE Integrated
Controller. REMOVE
Service as necessary
breakout box.
processor.
Integrated Controller connected. RE-EVALUATE
Key on, engine off. symptom.
For 3.8L:
- Jumper Test Pin 41 to Test Pin 40 at breakout
box.
For all others:
- Jumper Test Pin 52 to Test Pin 40 at breakout
box.
Does fan speed change from low to high?
X27 I CHECK ECT SENSOR
Key off, wait 10 seconds. Yes ~ For 3.8L SEFI SC:

GO to IX2SI.
Connect processor to breakout box. For all others:
REPLACE processor.
Check engine coolant level. REMOVE breakout box.
RECONNECT all
Warm engine to operating temperature before components.
taking ECl resistance measurement. RE-EVALUATE
Key off, wait 10 seconds. symptom.
Disconnect ECT sensor.

No ~ REPLACE ECT sensor.
RECONNECT all
Measure resistance of the ECT sensor. components.
Is the resistance between 1500 ohms and 2000 RE-EVALUATE
symptom.
ohms?

ALL RIGHTS RESERVED
IIntegrated Control1~r Pinpoint

Test
x
X28 ICHECK AlC PRESSURE SWITCH HARNESS

CONTINUITY

Disconnect AIC? pressure switch. REMOVE breakout box.
RECONNECT all
DVOM on 200 ohm scale. components. RERUN
Measure resistance between Test Pin 2 at the Quick Test.
breakout box and AIC pressure circuit at switch
breakout box and SIG RTN circuit at the switch
vehicle harness connector. ..
X29 I VERIFY HEDF OPERATION
Key off. Yes ~ REPLACE AIC

PRESSURE switch.
Breakout box installed, processor connected. RE-EVALUATE
AIC pressure switch disconnected. symptom.
Jumper AIC pressure circuit to SIG RTN circuit at

the switch vehicle harness connector.
Key on. RERUN Quick Test.
Is HEDF on?
X30 ISERVICE CODE 83:

CHECK HEDF CONTROLLER RESISTANCE
Service Code 83 indicates a High Electro Drive Fan Yes ~ GO to IX311.

(HEDF)/circuit failure.
Key off.
Controller. RERUN
Disconnect Integrated Controller. Quick Test.
Measure resistance between Pin 17 and Pin 24 at
the Integrated Controller.
Is resistance between 50 ohms and 100 ohms?

ALL RIGHTS RESERVED
Pinpoint
x
X31 I CHECK HEDF CIRCUIT CONTINUITY
Key off. Yes ~ GO to IX32\.

for damaged or pushed out pins, corrosion, loose No ~ SERVICE open in
HEDF circuit. REMOVE
breakout box.
components. RERUN
Integrated Controller disconnected. Quick Test.
For 3.8L:
breakout box and Pin 17 of the Integrated
For all others:
- Measure resistance between Test Pin 52 at
breakout box and Pin 17 of Integrated
X321 CHECK HEDF CIRCUIT FOR SHORTS TO

GROUND

Integrated Controller disconnected. ground in HEDF circuit.
RECONNECT all
For all 3.8L: components. RERUN
Quick Test.
For all others:

ALL RIGHTS RESERVED

Test
x
X331 CHECK HEDF CIRCUIT FOR SHORTS TO .. .

. POWER
Key off. Yes ~ REPLACE Processor.

RECONNECT all
Integrated Controller disconnected. components. RERUN
Quick T~st.
DVOM on 200,000 ohms scale.
For 3.8L:
-. Measure 'resistance between Test Pin 41 and
power. REMOVE
Test Pin 37 at the breakout box. breakout box.
For all others: RECONNECT all
components. RERUN
- Measure resistance between Test Pin 52 and Quick Test. If code 83
Test Pin 37 at the breakout box. is still present,
Is resistance greater than 10,000 ohms? R"EPLACE processor.
RERUN Quick Test.
X35 I LOW SPEED FAN ALWAYS ON

for damaged or pushed out pins, corrosion, loose No ~ SERVICE open in EDF
wires. Service as necessary. circuit. REMOVE
Install breakout box, leave processor disconnected. breakout box.
RECONNECT all
Disconnect Integrated Controller. components.
1...
symptom.
the breakout box and Pin 14 at the Integrated .
~
X36 I CHECK EQF CIRCUIT FOR SHORTS TO

POWER , .

.. ~ Integrated Controller disconnected. No ~ SERVICE short to
power in EDF circuit.
DVOM on 200,000 ohm scale. GO to I X371. '
Pin 37 and between Test Pin 55 and battery
positive post.

ALL RIGHTS RESERVED
Pinpoint
x
X37 I CHECK EDF FOR SHORT TO GROUND
Key on, engine off. Yes ~ REPLACE controller.

Breakout box installed, processor disconnected. RECONNECT
Connect Integrated Controller. processor.
RE-EVALUATE
Jumper Test pin 55 to Test Pin 40 or 60 at the symptom.
breakout box.
Does fan continue to run? No ~ REPLACE processor.
RECONNECT controller.
REEVALUATE
symptom.
X38 I CHECK AIC PRESSURE SWITCH INPUT
Key off. Yes ~ RECONNECT AIC

pressure switch. GO to
Disconnect AIC pressure switch. IX391.
Key on, engine off.
Does fan still run?
No ~ REPLACE the AIC
pressure switch.
RE-EVALUATE
symptom.
X391 CHECK Alc PRESSURE SWITCH CIRCUIT FOR

SHORTS TO GROUND
Key on. Yes ~ GO to IX3sl.

for damaged or pushed out pins, corrosion, loose No ~ SERVICE short circuit.
wires. Service as necessary. REMOVE breakout box.
RECONNECT all
Install breakout box, leave processor disconnected. components.
RE-EVALUATE the
Disconnect Integrated Controller. symptom.
Measu're resistance between Test Pin 2 and Test
Pins 40, 46, arid 60 at the breakout box.

ALL RIGHTS RESERVED
Pinpoint
I" Integrated CObtroller
Test
x
X40 CHECK FAN VOLTAGE
Key off. " Yes ~ GO to IX411.

Disconnect Integrat~d Controller:
DVOM on 20 volt scale. battery power circuit.
Measure voltage between battery negative post RECONNECT
and Pins 1 and 2 at the Integrated Controller Integrated Controller.
vehicle harness connector. RE-EVALUATE
symptom.
Is each Yoltage greater than 10.5 YOIts?

No ~ GO to IX431.
Does fan run?
X42 CHECK FAN RUNNING MODE

No ~ GO to IX441.
Connect Integrated Controller.
Key on, engine off.
Does fan run?'
. X43 MEASURE SATTERY VOLTAGE SUPPLY

AT FAN - BYPASSING INTEGRATED
CONTROLLER
Key off. Yes ~ REPLACE FAN.

RECONNECT all
Disconnect cooling fan. components.
symptom.
Jumper Pin 1 to Pin 3 a~ Integrated Controller
No ~ GO to IX4SI.
connector.

ALL RIGHTS RESERVED

Test
x
X44 ICHECK EDF CIRCUIT FOR SHORT TO

GROUND
Key off. Yes ~ . REPLACE Integrated

Controller.
Processor and Integrated Controller disconnected. RECONNECT
DVOM on 200,000 ohm scale. processor.
RE-EVALUATE
Measure resistance from Pin 14 to Pin 15 at symptom.
Integrated Controller vehicle harness connector.
Is resistance greater than 10,000 ohms? No ~ SERVICE short to
ground in EDF circuit.
RECONNECT all
components.
RE-EVALUATE
symptom.

RE-EVALUATE
DVOM on 20 volt scale. No ~ SERVICE open in
cooling fan vehicle harness connector and of Integrated Controller
negative battery post. vehicle harness
connector to cooling
Is Yoltage greater than 8.0 Yolts? fan vehicle harness
connector.
RECONNECT all
components.
RE-EVALUATE
symptom.

ALL RIGHTS RESERVED

Test
x
X46 I CHECK ECT SENSOR

RECONNECT ECT
Reconnect processor. sensor. RE-EVALUATE
Check engine coolant level. symptom.
Warm engine to operating temperature before
taking ECT resi.stance measurement. . No . ~ REPLACE ECT sensor.
RECONNECT all
Key off, wait 10 seconds. components.
RE-EVALUATE
Disconnect ECT sensor.
symptom.
Measure resistance of the ECT sensor. ...
Is the resistance between 1500 ohms and 2~00

ohms? . '
X50 I CHECK FOR VOLTAGE AT AIC CLUTCH
Disconnect AIC clutch. Yes ~ GO to Ventilatingl

s
Key on, engine off. Manual Group, AIC
AIC demand switch to AIC ON position. Diagnosis.
Start engine.
No ~. GO to IX511.
Check voltage at AIC clutch vehicle harness
connector.
. '
Is voltage greater than 10.5 Yolts?
X51 ICHECK FOR CONTINUITY FROM INTEGRATED

CONTROLLER TO AIC CLUTCH . .
Key off. Yes

, ~ RECONNECT
Integrated Controller. .
AIC clutch disconnected. GO to IX521.
Measure resistance between Pin 23 of the
No . SERVICE open in
power to AIC clutch or
ground to AIC clutch.
Integrated Controller vehicle harness connector RECONNECT
and power side of the AIC clutch vehicle harness' Integrate<;f Controller.
connector and between Pin 16 of the Integrated RE-EVALUATE
'Controller vehicle harness connector and ground . symptom.
side of the AIC clutch vehicle harness connector.

ALL RIGHTS RESERVED
Pinpoint
x
X52 I
ENTER OUTPUT STATE CHECK (REFER TO
IX531.
Disconnect processor 60 pin connector. Inspect No ~ DEPRESS throttle to
for damaged or pushed out pins, corrosion, loose WOT and RELEASE. If
wires, etc. Service as necessary. STO voltage does not
go high, LEAVE
Install breakout box and connect processor to equipment hooked up
breakout box. and GO to Pinpoint
Test Step IQC11.
control servo; if so equipped.
Connect DVOM negative test lead to STO and
positive test lead to battery positive.
Jumper STI to SIGNAL RETURN.
DVOM will indicate zero volts.
.
Old DVOM reading change to a high Yoltage
reading?
""
X531 CHECK WAC OUTPUT FOR PROPER

ELECTRICAL OPERATION

AIC demand sWi~ch to AIC ON position.
No ~ GO to IX571.
Connect DVOM positive test lead to Test Pin 37
and negative test lead to Test Pin 54 at the
breakout box.
While observing DVOM, depress and release the I
throttle several times.
Does Yoltage output change?

ALL RIGHTS RESERVED
Integrated Controller I ,Pinpoint x

I, - Test
X54 ICHECK FOR yOLTAGE AT AIC CLUTCH

SWITCH

AIC demand switch to AIC ON position.
DVOM on 20 volt scale. No ~ GO to IX561.
X55 ICHECK CONTINUITY OF ACCS CIRCUIT TO

INTEGRATED CONTROLLER -
Key off, wait 10 seconds. Yes ~ REPLACE Integrated
- Controller. REMOVE
breakout box.
Disconnect processor. RECONNECT
Disconnect Integrated Controller. processor.
RE-EVALUATE
DVOM on 200 ohm scale. symptom.
ACCS circuit. REMOVE
Is resistance less than 5 ohms? breakout box.
RECONNECT all
components.
RE-EVALUATE
symptom.
X56 I CHECK ACCS CIRCUIT CONTINUITY
Key off, wait 10 seconds. No ~ SERVICE open in

circuit. REMOVE
breakout box.
AIC demand switch to AIC ON position. RECONNECT all
DVOM on 200 ohm scale. components. RERUN
Quick Test.
breakout box and AIC demand switch.
Yes ~ EEC-IVsystem OK. '
RECONNECT all
VentilationlClimate
Control Shop Manual
Group for AIC
diagnosis.

ALL RIGHTS RESERVED
Pinpoint
x
X571 CHECK CONTINUITY IN WAC TO INTEGRATED

CONTROLLER CIRCUIT .
Key off, wait 10 seconds. No ~ SERVICE open in WAC

circuit. REMOVE
Breakout box installed. breakout box.
RECONNECT all
components.
Disconnect Integrated Controller. RE-EVALUATE
symptom.
Measure resistance between Test Pin 54 at the Yes ~ GO to IX581.
breakout box and ,Pin 22 at Integrated Controller
harness.
X5S1 CHECK WAC CIRCUIT FOR SHORTS TO

GROUND .
Key off, wait 10 seconds. Yes ~ GO to IX591.

Breakout box'installed, processor disconnected.
No ~ SERVICE shorts to
Integrated Controller disconnected. ground in WAC circuit.
RECONNECT all
Measure resistance between Test Pin 54 and Test components.
Pin 40 and between Test Pin 54 and Test Pin 46 RE-EVALUATE
and between Test Pin 54 and battery negative symptom.
post.
X591 CHECK
POWER
WAC CIRCUIT FOR SHORTS TO
.
Key off, wait 10 seconds. Yes ~ GO to IX601.

Integrated Controller disconnected. power in WAC circuit.
RECONNECT all
Measure resistance between Test Pin 54 and Test components. GO to
Pin 37 and between Test Pin 54 and battery IX601.
positive.
Is each resistance: greater than 10,000 ohms?

ALL RIGHTS RESERVED
EEC-.IV Pinpoint Test Procedures 17-471
Pinpoint
x

"
X60 CHECK FOR VOLTAGE AT AIC CLUTCH

Connect Integrated Controller. components.
RE-EVALUATE
Disconnect AIC clutch. symptom.
AIC demand switch to AIC ON position.
DVOM on 20 volt scale. Controller. REMOVE
breakout box.
Key on, engine off.
RECONNECT all
Measure voltage at AIC clutch harness components.
connection. RE-EVALUATE
symptom.

CHECK EDF PROCESSOR SIGNAL TO
INTEGRATED CONTROLLER FOR SHORTS TO
GROUND
For fan always on with Code 88: Yes ~ SERVICE short to

GO to IX821. ground in EDF circuit.
RECONNECT all
For all others: components. RERUN
Quick Test.
Key off.
for damaged or pushed out pins, corrosion, and
No ~ GO to IX811.
loose wires, etc. Service as necessary.
Install breakout box, .Ieave processor disconnected.

ALL RIGHTS RESERVED
Pinpoint
x
X81 CHECK FAN RUNNING MODE

Connect integrated controller. components. RERUN
Quick Test.
Key on, engine off.
Does fan run at low speed? No ~ REPLACE Integrated
Controller. REMOVE
breakout box.
RECONNECT all
components. RERUN
Quick Test.
X82 FAN ALWAYS ON WITH CODE 88:

CHECK EDF PROCESSOR SIGNAL
TO INTEGRATED CONTROLLER CONTINUITY

for damaged or pushed out pins, corrosion, and No ~ SERVICE open in EDF
loose wires, etc. Service as necessary. circuit. REMOVE
breakout box.
DisconneCt Integrated Controller. components. RERUN
Quick Test.
X83 CHECK EDF CIRCUIT FOR SHORTS TO

POWER
Key off. Yes ~ SERVICE short to

power in EDF circuit,
Breakout box installed, processor disconnected. then GO to IX841.
DVOM on 200,000 ohm scale. No ~ GO to IX841.
Pin 37, and between Test Pin 55 and battery
positive.
Is each resistance less than 10,000 ohms?

ALL RIGHTS RESERVED
. I Pinpoint X
I",,-I_n_te_g_r_a_te_~_C_o_n_t_r_O_II_e_r_ _~ .~
--I . ,-_T_e_s..;...t_~ '--~_..;.--I
X84 I CHECK EDF CIRCUIT FOR SHORTS TO

GROUND .
Key off. Yes ~ REPLACE Integrated

Gontroller. REMOVE
Breakout box installed, processor disconnected. breakout box.
Connect Integrated Controller. RECONNECT all
components. RERUN
Key on, engine off. Quick Test.
Jumper Test Pin 55 to Test Pin 40 or 60 at the
breakout box. No ~ REPLACE processor.
Does fan continue to run? RECONNECT all
components. RERUN
-.
Quick Test.
X90
'.
I SERVICE CODE 95:
CHECK INERTIA SWITCH
Key On Engine Off Service Code 95 indicates that Yes ~ RECONNECT inertia
one of the following has occurred: switch. GO to IX91 I.
- Open circuit in or between the fuel pump and
N9 ~ REPLACE or RESET
FPM circuit (see schematic)
inertia switch. RERUN
- Poor fuel pump ground Quick Test.
- FUEL PUMP circuit short to power
- . Fuel pump relay contacts always closed
Locate and disconnect fuel pump inertia switch.
Measure resistance of the fuel pump inertia .
switch.
~
X91 I VERIFY THAT FUEL PUMP IS OFF

Listen for motor noise from fuel pump.
No ~ GO to IX92\.
Is fuel pump off?

ALL RIGHTS RESERVED
Pinpoint
x
X921 CHECK FOR FUEL PUMP RELAY

ALWAYS CLOSED
Key off.
Locate and disconnect Integrated Controller.
Yes . REPLACE Integrated
Controller. RERUN
Quick Test
Does fuel pump shut off when Integrated
Controller is disconnected?
power in POWER-TO-
PUMP/FPM circuit.
RECONNECT
RERUN Quick Test.
. X93 I CHECK FPM CIRCUIT CONTINUITY

wires, etc. Service as necessary. REMOVE breakout box..
RECONNECT all
components. RERUN
Disconnect Integrated Controller. Quick Test.
Measure resistance between FPM circuit at the
X941 CHECK FOR CONTINUITY BETWEEN

FPM CIRCUIT AND GROUND

RECONNECT
Integrated Controller disconnected. Integrated Controller.
Measure resistance between FPM circuit at the

breakout box and battery negative post. No ~ REMOVE breakout box.
RECONNECT all
.15 resistance less than 5.0 ohms? components. GO to
Fuel/Engine Shop
Manual Group, Electric
Fuel Pump for open in
.. Power-To-Pump circuit,
poor fuel pump ground,
open in fuel pump, etc.

ALL RIGHTS RESERVED
EECIV Pinpoint Test.Procedures 17475

Test
x

CHECK POWER-TO-PUMP(S) CIRCUIT
CONTINUITY
Service Code 96 indicates that when the fuel pump Yes ~ GO to IX961.
is being activated, power is not being supplied to
'the fuel pump. No ~ SERVICE open in
Key off, wait 10 seconds. POWER-TO-PUMP
Disconnect processor 60 pin connector. Inspect circuit between FPM
for damaged pins, corrosion, loose wires, etc. splice and the
Service as necessary. Integrated Controller.
Disconnect Integrated Controller. components. RERUN
Quick Test.
Measure resistance between the FPM circuit at
the breakout box and Pin 5 at the. Integrated
X96 CHECK FUEL PUMP OPERATION

RERUN Quick Test.
Connect Integrated Controller. No ~ REPLACE Integrated
DVOM on 20 volt scale. Controller. REMOVE
breakout box.
Connect DVOM between FPM circuit and Test Pin RECONNECT
processor. RERUN
While observing DVOM, turn key to on. Quick Test.
Does Yoltage increase to greater than 9.8 Yolts
for about 1 second after key is turned to on?
X97 MEASURE IDLE FUEL PUMP RELAY POWER

CIRCUIT CONTINUITY
Service Code 59 indicates the idle fuel pump is not Yes ~ GO to IX9SI.
receiving the appropriate supplied voltage.
Key off. No ~ SERVICE Idle Fuel
Disconnect Integrated Controller. Pump circuit.
RECONNECT
DVOM on 200 ohm scale. Integrated Controller.
Measure resistance between Pin 10 at the RERUN Quick Test.
Integrated Controller vehicle harness connector
and battery positive post.

ALL RIGHTS RESERVED
Pinpoint
x
I
X100 CONTINUOUS MEMORY CODE 95:
A Continuous Memory Code 95 indicates that one Yes ~ ISOLATE fault and
of the following intermittent conditions has occurred: SERVICE as necessary.
CLEAR Continuous
- Open circuit in or between the fuel pump and Memory Code 95 .
FPM circuit in the processor (see (REFER to Quick Test
schematic (0). Appendix). RERUN
Quick Test.
- Poor fuel pump ground.
Start engine. No ~ GO to IX1011.
Check for engine stall/stumble while performing
the following (also, if possible, listen for fuel pump
turning off).
- Shake, wiggle, bend the power-to-pump circuit
between the Integrated Controller Pin 5 and
the fuel pump.
- Shake, wiggle, bend the fuel pump ground
circuit from the fuel pump to ground.
- Lightly tap the inertia switch and the fuel
pump to simulate road shock.
Key off.
Inspect the fuel pump electrical connector and the
fuel pump ground for corrosion, damaged pins,
etc.

ALL RIGHTS RESERVED
EECIV Pinpoint Test Procedures' 17477
Pinpoint
x
X101 CHECK FPM CIRCUIT
Key off. Yes ~ ISOLATE fault and

Disco.nnect processor 60 pin connector. Inspect REMOVE breakout box.
for damaged or pushed out pins, corrosion, loose RECONNECT
wires, etc. Service as necessary. processor. CLEAR
Continuous Memory
Install breakout box, leave processor disconnected. Code 95 (REFER to
Connect a test lamp between FPM circuit and Quick Test Appendix).
Test Pin 37 at the breakout box. RERUN Quick Test.
Key on: engine off.

Observe test lamp for an indication, of a fault and/or identify fault at
while performing the following (The light will go this time. For further
out when a fault is found indicating an open): diagnosis using the
EEC-IV Monitor Box,
- Shake, wiggle, bend the fuel pump monitor REFER to Section 18
circuit (Pin 8) between the processor and EEC-IV Monitor Box:
splice into the POWER-TO-PUMP(s) circuit. Intermittent Fault
Diagnosis.
. Is fault fou",d/indicated?
All others, CLEAR
Continuous Memory
(REFER to Quick 1est
Appendix). RERUN
: Quick Test.
X102 CONTINUOUS MEMORY CODE 59 or 96:

CHECK FOR CONTINUOUS MEMORY CODE 83
or 87
Is Continuous Memory Code 83 or 87 also Yes ~ GO to IX104\.

present?
I
No ~ GO to IX10a/.

ALL RIGHTS RESERVED

Test
x
X1031 CHECK EEC-IV HARNESS
A Continuous Memory Code 59 or 96, without the Yes ~ ISOLATE fault and
presence. of a Continuous Memory Code 83 or 87, SERVICE as necessary.
indicates that during vehicle operation, one of the CLEAR Continuous
following has occurred: Memory (REFER to
- Fuel pump relay contacts opened. RERUN Quick Test.
- Open in the POWER-TO-PUMP(s) circuit from
the Integrated Controller Pin 5 to the FPM No ~ Unable to duplicate
splice. (See schematic 00 ). and/or identify fault at
Start engine. diagnosis using the
EEC-IV Monitor Box,
Check for engine stall/stumble while performing REFER to Section 18
the following (also, if possible, listen for fuel pump EEC-IV Monitor Box:
turning off): Intermittent Fault
Diagnosis.
- Shake, wiggle, bend the POWER-TO-PUMP
circuit from the Integrated Controller to the
All others, CLEAR
FPM splice. Continuous Memory
- Lightly tap the Integrated Controller (to (REFER to Quick Test
simulate road shock). Appendix). RERUN
Quick Test.
Key off.
Inspect the Integrated Controller 24 pin
connectors for corrosion, damaged pins, etc.

ALL RIGHTS RESERVED

Test
x
X1041 CONTINUOUS MEMORY CODE 83 or 87:

A Continuous Memory Code 83 or 87 indicates that Yes ~ ISOLATE fault and

one of the following intermittent conditions has SERVICE as necessary.
occurred: CLEAR Continuou~ "
- Open VPWP circuit in the Integrated Controller. Memory Service
Code(s) (REFER to
- Open coil in fuel pump relay. Quick Test Appendix).
- Open in fuel pump primary circuit. RERUN Quick Test.
Start engine.
Check for engine stall/stumble while performing No ~ Unable to duplicate
the following (also, if possible, listen for fuel pump arid/or identify fault at
turning off): this time. For further
- Shake, wiggle, bend the EEC-IV Harness fuel diagnosis using the
EEC-IV Monitor Box,
pump circuit (Pin 22) between the processor
and the Integrated Controller (Pin 18). REFER to Section 18
EEC-IV Monitor Box:
or:
Intermittent Fault
- Shake, wiggle, bend the EEC-IV harness fuel Diagnosis.
pump circuit (Pin 41) between the processor
and the Integrated Controller (Pin 11). All others, CLEAR
- Lightly tap the Integrated Controller (to Continuous Memory
simulate road shock). (REFER to Quick Test
~ppendix). RERUN
Key off.
Quick Test.
Inspect the processor 60 pin connectors and" the
Integrated Controller 24 pin connector for
corrosion, damaged pins, etc.

ALL RIGHTS RESERVED
SECTION 18
EEC-IV Monitor Box:

Intermittent Fault Diagnosis
Contents
Diagnostic Flowchart 18-1
Introduction 18-2
Step 1: Visual Check 18-3
.Step 2: Vehicle Preparation 18-3
Step 3: Equipment Set-up 18-3
Step 4: Power Check 18-4
Step 5: Monitor Preliminary Check 18-4
Step 6: EEC-IV Power Checks 18-4
Step 7: EEC-IV Ground Checks 18-5
Step 8: Symptom Charts 18-6
Step 9: Road Test 18-21
Step 10: Analyzing Data 18-23
Appendix:
Methods of EEC-IV Monitor Measurements 18-27
Diagnostic "Reference Value Sheets 18-30
EEC-IV Graphs & Charts 18-56

ALL RIGHTS RESERVED
EEC-IV .Monitor Box: Intermittent Faul~ Diagnosis 18-1
EEC-IV MONITOR: Diagnostic Flowchart
VOL H DIAGNOSIS
SECTION 18
STEP 1: VISUAL CHECK
STEP 2: VEHICLE
PREPARATION
STEP 3: EQUIPMENT
SET-UP
STEP 4: POWER CHECK

STEP 5: MONITOR PRELIMINARY
CHECKS
STEP 6: EEC-IV POWER CHECKS
STEP 7: EEC-IV GROUND CHECKS
STEP 8: SELECT 1 OF 14
SYMPTOM CHARTS
f-o---------------
PERFORM VISUAUMECHANICAL CHECKS
SELECT EEC-IV SIGNALS TO CHECK
STEP 9: ROAD'TEST ....._ _ APPENDIX:' DIAGNOSTIC REFERENCE

COLLECT DATA VALUE SHEETS
, . . . . . - - - - - - -......"i.~
STEP 10: ANALYZING DATA APPENDIX: EEC-IV GRAPHS
..,...~--
TEST "SUSPECT': EEC-IV AND CHARTS

INPUT DEVICES OUTPUT
SIGNALS I
SIGNALS
2 WIRE 3 WIRE
SENSORS SENSORS SWITCHES OTHER SOLENOIDS OTHER
I STRATEGy'l, STRATEGY I. 1STRA!EGY I ISTRATEGY I ISTRATEGY I STRATEGY I

I I 1 ' J. 1
-
- - ,
NO. ~ I IS FAULT I..-_ _~N~O~,E~V~E~R~YT_H_I_N_G ....~,., OPTIONS:

IFOUND? I CHECKED * AUX TESTING
, YES * OTHER TESTING
IREPAIR, VERIFY'
AND RE.TEST
* ANOTHER ROAD TEST
* VOL H, SECTION 2
A12801-B

ALL RIGHTS RESERVED
18-2 EEC-IV Monitor Box: Intermittent Fault Diagnosis
EEC-IV MONITOR: Introduction
DEFINING INTERMITTENT DRIVEABILITY SYMPTOMS
The EEC-IV Monitor* and the EEC-IV Monitor Recorder* are useful tools for diagnosing
intermittent driveability symptoms which are unable to be resolved through the diagnostics in
Section 17 Pinpoint testing. This section supports diagnostic procedures and data using the
Monitor and Recorder in a symptom-oriented manner.
By definition 'intermittent' is a randomly occurring drive symptom for which no hard codes
(KOEO, KOER) are revealed by the STAR tester. Often the Quick Test results in "Pass
Codes" while the drive symptom still exists. Other results, such as Continuous Memory Codes,
will also apply to the scope of this section.
Before proceeding with the following procedure, be sure that:
Customary mechanical system tests and inspections reveal nothing. (Remember,

mechanical component problems can make a good EEC system react abnormally.)
Quick Test (Section 14) and associated Pinpoint diagnosis (Section 17) have been
completed, but the symptom is still occurring.
Review of Ford Technical Service Bulletins (TSB's) and inquiry into OASIS turns up no
applicable articles.
PURPOSE OF THIS SECTION
The Monitor and Recorder function as a 'window' into the EEC-IV system. Through this
'window' the user is able to view the same sensor values and signals the EEC-IV module is
outputting to the actuators. The EEC-IV module uses these values to make decisions which
increase engine performance. The Monitor displays these values for both engine off (KOEO)
and engine running conditions (KOER). The advantage of the Recorder is the ability to take a
'snapshot' of selected EEC-IV signals which can be stored and reviewed simultaneously.
A basic working knowledge of the EEC-IV system is critical to efficient troubleshooting of the
symptom. No diagnostic procedure can account for all the possibilities which can be
encountered, therefore this diagnostic procedure only attempts to provide basic steps and
methods for isolating possible causes.
The diagnostic procedure used in this section is a symptom-based approach to isolating the
faulty system, circuit or sensor. Often a mechanical fault will cause a good EEC-IV system to
react abnormally. In those cases, the use of a Monitor with this diagnostic procedure will
enhance the opportunity to eliminate possible EEC-IV faults and also locate mechanical faults.
* NOTE: In this section, the EEC-IV Monitor and EEC-IV Monitor Recorder will be
referred to as Monitor and Recorder, respectively.

ALL RIGHTS RESERVED
EEC-IV Monitor Box: Intermittent Fault Diagnosis 18-3
EEC-IV MONITOR: Visual Check, Vehicle Step

Preparation and Equipment Set-up 1-3
STEP 1 1 VISUAL CHECK
Check vacuum hoses for damage and proper Yes ~ GO to Step [!] .
connection.
Check EEC-IV system wiring harness for proper No ~ SERVICE as necessary.
connections.
..
Visual Check, refer to Section 14 Quick
Test Appendix.
Are all visual checks OK?
STEP 2 I VEHICLE PREPARATION
Apply parking brake. Yes ~ ..GO to Step [I] . ,.
Place shift lever firmly in PARK (NEUTRAL for

manual transmissions). No ~ REPEAT Step rn .
Block drive wheels. NOTE: If engine does
Turn off all electrical loads. not start or stalls
after starting,
Start engine and run until at operating continue to Step [I] .
temperature. (ECT = .6V or 200F)
NOTE: If additional information is required for
Vehicle Preparation, refer to Section 14
Quick Test Appendix.
.-
Is vehicle prepared for Equipment Set-up?
STEP 3 1 EQUIPMENT SET-UP
Perform KOEO Self-Test and check for Continuous Yes ~ Proceed with Step [!J ,
- Memory Codes. These codes must be recorded Power and Ground
before disconnecting the EEC-IV harness, Checks.
otherwise they could be erased.
Key off. No ~ REPEAT Step [I] .
Install Monitor using 10mm wrench or nutdriver.
Refer to installation procedure in Monitor Manuals,
if needed.
Select proper Monitor overlay card for the
appropriate .engine.
If a Recorder is available, do not install at this
time.
Is Monitor installed and the connecting cable
safely routed away from moving parts and
Ignition components?

ALL RIGHTS RESERVED
184 EECIV Monitor Box: Intermittent Fault Diagnosis
EEC-IV MONITOR: Monitor and EEC-IV .Step

Power and Ground Checks 4-6
STEP 4 I POWER CHECK
Key off, Monitor power switch Off. Yes ~ GO to Step I]] .

Is KAPWR (pin 1) green light on?
No ~ REPAIR battery or
KAPWR circuit.
STEP 5 I MONITOR PRELIMINARY CHECKS
Key off, Monitor power switch On. Yes ~ GO to Step 00.

Perform the following tests to ensure the Monitor
is functional: No ~ Monitor needs to be
- Light Test - Move Monitor lamp switch to on. repaired. REFER to
Are all panel lamps lit (including 6 lamps in address posted on lid
remote display) and does audible beep sound? of Monitor.
- Remote Display Test. Push button on remote
display unit.
Does it read - 1888?
NOTE: Temperature extremes will affect remote
display unit. Above 150F, a black display
will result; at cold temperatures the
display will run slow.
Are all tests OK?
STEP 6 I EECIV POWER CHECKS
Key on, engine off. Yes ~ GO to Step [I] .

Monitor ON, AUTO mode.
Check the following power signals for the correct No' ~ REPAIR harness
. value. Refer to Chart 1 - EEC-IV Power Signals. connector or other
Are all. power signals at the correct values? possible faults listed in
Chart 1.
Chart # 1
EECIV Power Signals
Signal Value Possible Fault Location
KAPWR >10.5v EEC-IV harness pin 1, vehicle battery.
VPWR >10.5v EEC-IV harness pin 37/57, power relay or IRCM,
vehicle battery, ignition switch, battery cables.
VREF 4.5 - 5.5v EEC-IV harness pin 26, EEC-IV processor.
KEYPWR (opt) >10.5v EEC-IV harness pin 5, vehicle battery, ignition switch.-

ALL RIGHTS RESERVED
EEC-IV MONITOR: Monitor and EEC-IV

Step 7
Power and Ground Checks
STEP 7 I EEC-IV GROUND CHECKS
Key on, engine off. Yes ~ GO to Step [I] ,

Monitor ON, AUTO mode. Symptom Charts.
Check the following ground signals for the correct
value. Refer to Chart 2 - EEC-IV Ground Signals. No ~ REPAIR harness,
Are all ground signals at the correct values? connector or other
possible faults listed in
Chart 2.
Chart # 2
.EEC-IV Ground Signals
SIGNAL Value Possible Fault Location

CSE GND o .5v EEC-IV harness Pin 20, processor. ground strap if
applicable.
IGN GND o .5v EEC-IV harness Pin 16, TFI-IV, DIS or EDIS ignition
systems. .
PWR GND o .3v EEC-IV harness Pin 40/60, vehicle battery.
SIG RTN o .5v EEC-IV harness Pin 46, EEC-IV processor.
HEGO GND o .5v EEC-IV harness Pin 49, HEGO sensor.
MAF RTN (opt) o .5v EEC-IV harness Pin 9 or 15, MAF sensor, EEC-IV
processor.

ALL RIGHTS RESERVED
I
I
EEC-IV MONITOR: Symptom Charts Step 8
Select the appropriate Symptom Chart as a guide for diagnosing the possible mechanical,
electrical or EEC-IV faults. For each symptom, Visual/Mechanical Checks and EEC-IV Checks
are listed in a suggested order. Continue to STEP 9 - ROAD TEST SET-UP.
CONTENTS
STARTING/IDLE
No Start (Cranks) 18-7

Stalls at Idle/Engine Will Not Stay Running 18-8
Fast Idle/Slow Idle 18-9
Rough Idle 18-10
ENGINE RUN: STEADY SPEED/ACCELERATION/DECELERATION
Surges 18-11 .
Poor Power or Sluggish 18-12
Spark Knock 18-13
Stalls at Deceleration/Quick Stop 18-14
Runs Rough: Hesitates 18-15
Misses
Bucks and Jerks
Backfires
EEC-IV RELATED SHIFT SYMPTOMS
Late, Early, Missing or No Shifts 18-16

Hard or Soft Shifts 18-17
Erratic, Hunting Shifts 18-18
No Coastdown, No Overdrive 18-19
OTHER
Check Engine Light On 18-20

ALL RIGHTS RESERVED
No
I EEC-IV MONITOR: Symptom Charts
Start
. .
System Possible Causes.
Visual/Mechanical Checks EEC-IV Checks
Fuel Check fuel pump inertia switch. Fuel Pump System:
Check for fuel contamination/quality. FP signal
Check fuel filter. FPM signal
FP relay
Fuel Injection:
INJ (CFI)
INJ 1, 2 (EFI)
INJ 1, 2, .. (SFI)
Ignition Check distributor cap, adapter and rotor. "gnition System:
Inspect spark plug and plug wires. PIP signal
Check ignition switch. SPOUT signal
Check ignition ,coil for voltage. IGN GND
Inspect TFI, DIS or EDIS module for
damage.
Check for presence of anti-theft devices.
Power and Grounds Check for low battery voltage. EEC-IV power:
Check starter and starter circuit for VREF
voltage. VPWR/EEC-IV relay
Inspect electrical connections, wires and EEC-IV grounds:
harnesses. - SIG RTN
PWR GND
CSE GND
Air/Vacuum Check vacuum lines for leaks or wear. TP sensor
MAP/BP sensor
MAF sensor
ISC-BPA solenoid or ISC+
Other Check engine coolant level. ECT sensor
Check thermostat for proper operation. EPC s~lenoid (E40D)
Check EGR valve stuck open.
Check for moisture entry into EEC-IV
module.
Check camshaft timing and cylinder
compression.

ALL RIGHTS RESERVED
18-8 EEC-IV Monitor Box: Intermitten"t Fault Diagnosis
EEC-IV MONITOR: Symptom Charts Stalls
System Possible Causes

Ignition Check distributor cap, adapter and rotor. Ignition System:
Check ignition coil for voltage. IGN GND
damage.
Fuel Check Fuel Pump Inertia switch. Fuel Pump System:
FP relay
Fuel Injection:
INJ (CFI)
INJ 1, 2 (EFI)
INJ 1, 2 .. (SFI)
Power and Grounds Check for low battery voltage. EEC-IV Power:'
Inspect electrical connections, wires and VREF
harnesses. VPWR/EEC-IV relay
EEC-IV Grounds:
SIG RTN
PWR GND
CSE GND
Visual/Mechanical Checks EECIV Checks
MAP/BP sensor
MAF sensor
Check thermostat for proper operation. EPC solenoid (E40D)
Check EGR valve stuck open. EGR Systems:
Check for moisture entry into EEC-IV EVP or PFE sensor
module. EGR solenoid(s)
Check camshaft timing and cylinder PSPS switch
compression. A/C Systems:
ACC, ACCS, WAC, or
ACD

ALL RIGHTS RESERVED
Fast Idle
EEC-IV MONITOR: Symptom Charts
Slow Idle
System Possible Causes .

Air/Vacuum Check vacuum lines for leaks or wear. ISC-BPA solenoid or ISC+
Check air filter. MAP/BP sensor
MAF sensor
TP sensor
ACT sensor or VAT and
VAF sensor
Fuel Check for correct fuel pressure. HEGO sensor
Check for fuel contamination/quality. Fuel Injections:
Check fuel filter. INJ (CFI)
INJ 1, 2 (EFI)
INJ 1, 2 .. (SFI)
Ignition Check for correct base timing. Ignition System:
Check distributor cap, adapter and rotor. SPOUT signal
I
Inspect spark plug and plug wires. SAW signal
damage.
Power and Grounds Check for low battery voltage. EEC-IV Power: VREF
Inspect electrical connections, wires and EEC-IV Grounds: SIG RTN
harnesses.
. ,
Other Check coolant and engine oil levels. ECT sensor
Check thermostat for proper operation. EGR Systems:
Check EGR valve sticking. EVP or PFE sensor
Check for PCV valve for correct operation. EGR solenoid(s) -
Check for exhaust blockage.' A/C Systems:
ACC, ACCS, WAC or
ACD
NDS switch
PSPS switch

ALL RIGHTS RESERVED
Rough
Idle

Check air filter. MAP/BP sensor
MAF sensor
TP sensor
VAF sensor
Check for fuel contamination/quality. Fuel Pump System:
Check fuel filter. FP signal
FPM signal
FP relay
Fuel Injection:
INJ (CFI)
INJ 1, 2 (EFI)
INJ 1, 2 .. (SFI)
CAN P solenoid
Ignition Check for correct base timing. Ignition System: CID signal
Check distributor cap, adapter and rotor.
Inspect spark plug and plug wires.
damage.
Power and Grounds Check for low battery voltage. EEC-IV Power: VREF
Inspect electrical connections, wires and EEC-IV Grounds: SIG RTN
harnesses.
Check thermostat for proper operation. EGR Systems:
Check EGR valve sticking. EVP or PFE sensor
Check for PCV valve for correct operation. . EGR solenoid(s)
Check for exhaust blockage. A/C Systems:
ACC, ACCS, WAC or
ACD

ALL RIGHTS RESERVED
.EEC-IV MONITOR: Symptom Charts Surges

Air/Vacuum Check vacuum lines for leaks' or. wear. TP sensor
MAP/BP sensor
MAF sensor
Visual/Mechanical Checks < EEC-IV Checks
Fuel Check for correct fuel pressure. Fuel Injection:
Check fuel lines for water contamination INJ (CFI)
restrictions. INJ 1, 2 (EFI)
INJ 1, 2 .. (SFI)
.HEGO sensor
Visual/Mechanical Checks .; EEC-IV Checks
Ignition Check for correct base timing. ignition System:
Inspect TFI, DIS or EDIS module for .. PIP signal
damage. SPOUT signal
Visual/Mechanical Checks ': . .EEC-IV Checks
Other Check EGA valve sticking;' ,. EGA Systems:
Check for PCV valve for correct operation. EVP or PFE sensor
Check for exhaust blockage. ' EGA solenoid(s)
Inspect electrical .connections, wires and. SBS solenoid
harnesses. ;

ALL RIGHTS RESERVED
Poor Power
EEC-IV MONITOR: Symptom Charts or
Sluggish

~ MAP/BP sensor
MAF sensor
Check fuel lines for contamination or INJ (CFI)
Check for clogged fuel filter. INJ 1, 2 .. (SFI)
Check for wear or corrosion in distributor. PIP signal
Inspect TFI, DIS or EDIS module for SPOUT signal
damage. DPI signal
Other Check EGR valve sticking. EGR Systems:
Check for exhaust blockage. EGR solenoid(s)
Inspect electrical connections, wires and AM 1 solenoid
harnesses. AM2 solenoid
Check for partially binding brakes. EPC solenoid (E40D)
CCC solenoid (E40D)

ALL RIGHTS RESERVED
EECIV Monitor Box: Intermittent Fault Diagnosis 1813
Spark
I Knock

. Visual/Mechanical Checks EECIV Checks
MAP/ BP sensor
MAF sensor
ACT sensor or VAT
and VAF sensor
Check for wear or corrosion in distributor. PIP signal
Inspect TFI, DIS or EDIS module for SPOUT signal
damage.
Check fuel lines for contamination or INJ (CFI)
INJ 1, 2 .. (SFI)
Other Check EGA valve sticking. EGA Systems:
Check for PCV valve for correct operation. EVP or PFE sensor .
Check for exhaust blockage. EGA solenoid(s)
Check engine coolant level. KS sensor
Check thermostat for proper operation. ECT sensor
Inspect electrical connections, wires and
harnesses.

ALL RIGHTS RESERVED
'. 18-14 EECIV Monitor Box: Intermittent Fault Diagnosis
Stalls at
EEC-IV MONITOR: Symptom Charts Deceleration
or Quick Stop

MAP/BP sensor
MAF sensor
ACT or VAT and VAF
sensor
Ignition Check distributor cap, adapter and rotor. Ignition System:
Check ignition coil for voltage. IGN GND
damage.
Check Fuel Pump Inertia switch. Fuel Pump System:
Check fuel lines for water, dirt or rust. FP relay
Fuel Injection:
INJ (CFI)
INJ 1, 2 (EFI)
INJ 1, 2, .. (SFI)
Power and Grounds Check for low battery voltage. EEC-IV Power:
Inspect electrical connections, wires and VREF
harnesses. VPWR/EEC-IV relay
EEC-IV Grounds:
SIG RTN
PWR GND
CSE GND
Check thermostat for proper operation. EPC solenoid (E40D)
Check EGR valve sticking. EGR Systems:
Check for moisture entry into EEC-IV EVP or PFE sensor
module. EGR solenoid(s)
. Check camshaft timing and cylinder A/e Systems:
compression. ACC, ACCS, WAC or
ACD

ALL RIGHTS RESERVED
Runs
Rough

MAP/BP sensor
MAF sensor
TP sensor
VAF sensor
Check for fuel contamination/quality. Fuel Pump System:
". Check fuel filter. FP signal
"
FPM signal
FP relay
Fuel Injection:
INJ (CFI)
INJ 1, 2 (EFI)
INJ 1, 2 "" (SFI)
Visual/Mechanic~1 Checks . EECIV Checks
Check distributor cap, adapter and rotor. PIP signal
Inspect spark plug and plug wires. SPOUT signal
Inspect TFI,. DIS or EDIS module for CID signal
damage.
Power and Grounds Check for alternator/regulator noise EEC-IV Power: VREF
interference.
Inspect electrical connections, wires and, EEC-IV Grounds: SIG RTN
harnesses.
Check thermostat for proper operation. EGA Systems:
Check EGA valve sticking. EVP or PFE sensor
Check for PCV valve for correct operation. EGA solenoid(s)
Check for exhaust blockage. EPC solenoid (E40D)
Check camshaft timing and cylinder CCC solenoid (E40D)
compression.
Check for broken or weak valve springs.

ALL RIGHTS RESERVED
1816 EEC-IV Monitor Box: Intermittent Fault Diagnosis
Late, Early,
EEC-IV MONITOR: Symptom Charts Missing or
No Shifts

E40D Transmission Check transmission fluid level. S51 solenoid
Check transmission fluid for contamination. SS2 solenoid
Check for transmission fluid leaks. EPC solenoid
Check transmission line pressure. CCS solenoid
Check E40D connector for corrosion, bent CCS solenoid
pins or damage. OCS solenoid
MLP sensor
AXOD Transmission Check transmission fluid level. LUS solenoid
Check transmission fluid for contamination. NpS switch
Check for transmission fluid leaks.
Check transmission line pressure.
Check AXOD connector for corrosion,
bent pins or damage.
A4LD Transmission Check transmission fluid level. CCO solenoid
Check transmission fluid for contamination. SS 314 solenoid
Check A4LD connector for corrosion, bent
pins or damage.
Other Check engine coolant level. TP sensor
Check for worn, leaking or broken vacuum MAPIBP sensor
lines.
Inspect electrical connections, wires and MAF sensor
harnesses.
VSS sensor

ALL RIGHTS RESERVED
Hard or
Soft Shifts

E40D Transmission Check transmission fluid level. CCC solenoid
Check transmission fluid for contamination. CCS solenoid
Check for transmission fluid leaks. MLP sensor
Check transmission line pressure. EPC solenoid
Other Check engine coolant level. TP sensor
Check for worn, leaking or broken vacuum MAP/BP sensor
lines.
harnesses.
Check for damage to U-joints. VSS sensor

ALL RIGHTS RESERVED
Erractic
EEC-IV MONITOa: Symptom Charts or Hunting
Shifts

E40D Transmission Check transmission fluid level. SS1 solenoid
Check for transmission fluid leaks. CCC solenoid
Check transmission line pressure. EPC solenoid
Check E40D connector for corrosion, bent CCS solenoid
pins or damage. OCS switch
MLP sensor
Check transmission fluid for contamination. NPS switch
Check transmission fluid for contamination. SS 3/4 solenoid
pins or damage.
Other Check engine coolant level. Ignition System:
Check thermostat for proper operation. PIP signal
Check for worn, leaking or broken vacuum SPOUT signal
lines. TP sensor
Inspect TFI, DIS or EDIS module for ECT sensor
damage. MAP/BP sensor
harnesses. VSS sensor

ALL RIGHTS RESERVED
No Coastdown
EEC-IV MONITOR: Symptom Charts or
Overdrive

E40D Transmission Check transmission fluid level. OCS switch
Check for transmission fluid leaks. MLP sensor
Check transmission line pressure. SS1 solenoid
Check E40D connector for corrosion, bent
pins or damage.
Check transmission fluid for contamination. NPS switch
Check transmission fluid for contamination. SS 3/4 solenoid
pins or damage.

ALL RIGHTS RESERVED
"CHECK ENGINE
UGHT' On

MAP/BP sensor
MAF sensor
VAF sensor
ITS sensor
Ignition Check for correct base timing. Ignition System: 10M signal
Inspect EOIS module for damage.
Check for correct fuel pressure. HEGO sensor
Fuel Check fuel lines for water, dirt, rust or
restrictions.
Other Check EGR valve sticking. EGA Systems:
Check for exhaust blockage. ECT sensor
Check engine oil quality and level. STO/MIL signal
Check engine coolant quality and level. EEC-IV Power: VREF
Check thermostat for proper operation.. ' EEC-IV Ground: SIG RTN
Check MIL bulb and circuit for correct'
operation.
Inspect electrical connections, wires and
harnesses.

ALL RIGHTS RESERVED
EE~IV Monitor Box: Intermittent Fault Diagr:tosis 1821
EEC-IV MONITOR: Road Test Set-up Step 9
RECREATING THE SYMPTOM
In order to diagnose driveability concern, one must collect information on how the EEC-IV
system is sensing and reacting. After Visual/Mechanical checks are completed and satisfied,
the EEC-IV portion of the Symptom Chart is diagnosed. Through the use of Monitor and
Recorder, these signal lines can be in$pected for shorts, opens, component failures or erratic
behavior. In addition, the information received from the Monitor and Recorder can reveal the
presence of mechanical problems.
ROAD TEST SET-UP

1. Place Monitor (Recorder also, if installed) in convenient location inside the vehicle. Secure
cables away from moving engine parts.
2. Check to see if' the proper Overlay card is, inserted on Monitor.
3. Copy list of EEC-IV sensors and" actuators in order given by Symptom Chart. These
signals will be monitored during the road'test.
4. If a Recorder is used, then select the first 8 signals listed in the Symptom Chart for
Channels 1 to 8. Connect the jumpers from the I/O jacks to the appropriate channels.
5. Select the proper Diagnostic Reference Value Sheet in Appendix. This sheet lists EEC-IV
sensor and actuator values at various operating conditions. The values given on these
sheets are an approximation only.
6. In order for a road test to be performed it is required that another person accompany the'
driver. The accompanying person can select signals, observe changes and record notes.
USE OF PERIPHERAL INPUTS
Some useful signals which are listed in the Symptom Chart may require the use of certain
peripherals. These devices can be inserted into. the AUX input jacks of the Monitor or the
ADAPT 1/ADAPT 2 input jacks of the Recorder. Listed are two types of peripherals and
examples of the signals they receive.
Multi-Point Auxiliary Adapter - A/C, Fuel Pump
Electronic Fuel Pressure/Vacuum Adapter - Fuel Pressure, Vacuum

ALL RIGHTS RESERVED
EEC-IV MONITOR: Road Test Step 9
ROAD TEST REMINDERS
The purP9se of the road test is to recreate the drive symptom by duplicating the conditions
that caused it to occur.
Legality/Liability. The Road Test Procedure is a suggested but optional part of this section.
The liability of this operation is left to the individual who chooses to use it.
Safety. It is important that the road test is performed safely. Use the provided seat belts an~
operate the vehicle in a safe manner.
ROAD TEST OBSERVATIONS
During the road test various EEC-IV signals are chosen and their values shown. In addition, to
this data, certain observations can be made and road tests performed:
EEC-IV .Values. Compare road test values at various operating conditions with those listed in
the Diagnostic Reference Values. Refer to Appendix: EEC-IV Graphs and Charts for further
detail.
Monitor Lights. Observation of the Monitor lights give quick information about the condition of
many EEC-IV signals. For example, these lights can quickly reveal the general status of many
signals and tell whether a solenoid or switch is activated. Optional signals are printed in yellow
labels.
Wiggle Testing. By using the Monitor Wiggle test in KOER, often an intermittent device or
wire will trigger the beeper. The DCV Wiggle mode in particular is very sensitive to sudden,
erratic changes in an EEC-IV harness or component.
ROAD TEST PROCEDURE

1. Using the appropriate Symptom Chart, select the first listed EEC-IV device on Monitor
PIN SELECTOR A.
2. Turn on Monitor and Recorder if used. Start and drive vehicle.
3. If Recorder is installed put FUNCTION switch in RECORD mode and press START
RECORD button.
4. Drive vehicle to create conditions so that the symptom occurs.
5. When the symptom occurs, the accompanying passenger should observe changes in
selected EEC-IV signal. Information should be recorded onto paper with other specific
notes about the symptom, device, or operating conditions. If the Recorder is used, the
CAPTURE button should be pressed.
6. Record information about the symptom, operating condition and value of the EEC-IV signal
from the Monitor or Recorder (in PLAYBACK mode).
. 7. If necessary select other EEC-IV signals from the Symptom Chart and attempt to
recreate the symptom again. Observe and record the results. Continue onto Step 10 and
analyze the data which was collected during the road test.

ALL RIGHTS RESERVED
EEC-IVMonitor Box: Intermittent Fault Diagnosis 18-23
EEC-IV MONITOR: Analyzing Data Step 10
ANALYZING DATA
Once the road test is completed, the results need to be analyzed to locate and repair the
exact fault which caused the symptom.
INSIGHTS FROM THE RECORDER
The use of the Recorder greatly enhances the view of the EEC-IV operation during the
presence of the symptom and allows a systems approach to the problem.
Look for abnormal behavior or values that are clearly incorrect. Inspect the signals for
abrupt or unexpected changes. For example, during a steady crui~e most of the sensor values
should be relatively stable. Sensors such as TP, MAP and RPM changing abruptly when the
vehicle was travelling at a constant speed are clues.
Look for agreement in related signals. For example, if TP is changed during a gentle
acceleration, a corresponding change should occur in MAP, RPM and Timing. Compare signals
by selecting different channels at a certain time range.
. Make sure the signals act in proper sequence. An increase in RPM after the TP is
increased is expected. However, if the RPM increases without a TP change then a problem
exists.
ANALYZING METHODS
Use any of the following methods to further diagnose a suspected EEC-IV signal or device.
Some methods are particular to a certain type of EEC-IV device. Follow the given strategy
listed for each type of EEC-IV signal - Refer to the Appendix: Methods of EEC-IV Monitor
Measurement.
Change Condition to Cause Response by Input
Change Input and Verify Output Response
Check Value
Click Testing (Solenoids/Relays)
Coil Resistance (Solenoids/Relays)
EEC-IV Input Check (STO)
Harness Opens
Harn-ess Shorts
Output State Check (Solenoids/Relays)
Wiggle Testing (DCV or Ohms)

ALL RIGHTS RESERVED
ANALYZING DATA: Suggested Strategies for Sensors/Inputs

WIRE SENSORS
Device: Typical Schematic: Strategy:

ACT SIGNAL Check Value - Cold
ECT Check Value - Warm
TOT Wiggle Testing (OCV)
VAT
_______Y
SIGRTN 3 EEC-IV Input Check (STO)
Harness Shorts
Harness Opens
A 12802-A
WIRE SENSORS

EVP VREF Check Value
FIPL Change condition
PFE SIGNAL Wiggle Testing (OCV)
TP EEC-IV Input Check (STO)
SIG RTN
VAF Harness Shorts
Harness Opens
A12803-A
SWITCHES

ACO OCTAOJ Check value
BOO PSPS Change condition
CES SCCS Wiggle Testing (OCV)
SIGNAL ./
ITS
NOS
THS 3/2
THS 4/3
----cr 0--- Harness Shorts
Harness Opens
NGS
NPS TIS
OCS 4x4 L A 12804-A
OTHER INPUT SIGNALS

BP MAF Check value
CIO MAP Change condition
OPI MLP INPUT * Wiggle Testing (OCV or
EEC-IV
FPM PIP ......1 - - - - SIGNAL ohms)
PROCESSOR
HEGO RPMS Input Check (STO)
10M STI Harness Shorts
IMS VSS+ Harness Opens
A1280SB
KS Note: Applies only to BP,
MAF and MAP

ALL RIGHTS RESERVED
ANALYZING OATA: Suggested Strategies for Actuators/Outputs

SOLENOIOS/RELAYS

ACC HFP Check Value
AM1 lAC SIGNAL Change Input
AM2 INJ Click Testing
BOOST ISC-BPA Wiggle Testing (DCV)
CANP lUS Coil Resistance
CCC SBS . Output State Check
VPWR*
CCO SCVAC Harness Shorts
CCS SCVNT * EXCEPT SCVNT, SCVAC USES SOL + A12806-A Harness Opens
EDF SS1
EGRC SS2
EGRV SS 3/4
EGR S/O VPWR'
EPC WAC
EVR
FP
HEDF
OTHER OUTPUT SIGNALS

ACl Check Value
ISC+
Mil.
EEC-IV
- OUTPUT
Change Input
Wiggle Testing (Ohms)
OCll SIGNAL Harness Shorts
PROCESSOR
SAW Harness Opens
Sil
SPOUT
STO A 12807-B

ALL RIGHTS RESERVED
OPTIONAL DIAGNOSTIC TOOLS
By using the suggested strategies for the suspect' EEC-IV components the source of the
II I
fault can be found. If after following the given methods a fault is not found then a few
options still remain.
Follow-up Diagnosis. The Monitor and Recorder can be used to Diagnose EEC-IV signals
other than those listed in the chosen Symptom Chart. By conducting a thorough investigation
of all the EEC-IV signals, the source of the problem can likely be found. Available for auxiliary
(AUX) inputs are two peripherals: Multipoint Auxiliary Adapter (#007-00023) and the
Electronic Fuel Pressure/Vacuum Adapter (#007-00022).
Other Diagnostic Tools. If needed, there are other specialized tools that could aid in
Diagnose. The Intermittent Ignition Analyzer (# 007-00035) can be used for TFI-IV systems.
If a DIS or EDIS ignition is present, special diagnostic tools are necessary - refer to Section
13. Another useful tool is the Fuel Testing Kit (# 113-00004) used in' checking the presence
of contaminated fuel.
Section 2. The Diagnostic Routines, Section 2 of this volume, lists various symptoms and
references possible systems and components. Also referenced in this location are other
volumes and group numbers.
VERIFICATION
After the vehicle fault has been located and repaired, a verification test needs to be
performed. This may require a road test to verify that the symptom is no longer present. It is
also important to remember that if any Continuous Memory Codes were present before the
symptom was repaired, those codes must be cleared. Refer to Section 14 Appendix - How
to Clear Continuous Memory Codes.

ALL RIGHTS RESERVED
APPENDlX: Methods of EEC~IV Monitor' Measurements
Described here are ten basic methods to measure and diagnose EEC-IV signals. Other less
common methods are detailed in the Monitor manuals.
CHANGE CONDITION TO CAUSE RESPONSE BY INPUT

Purpose: Verify sensor receives and. reponds to changes;
-
1. KOEO or KOER; AUTO or DCV mode.
2. Select sensor on PIN SELECTOR A.
3. Create condition or change in condition.
4. Observe change in sensor value; verify with EECIV Graphs and Cha~ts.
5. Examples: Move throttle, observe TP increase, MAP increase.

. Warm-up engine, observe ACT, ECT decrease.
Press brake pedal, observe BOO light. .
CHANGE INPUT AND VERIFY OUTPUT RESPONSE

Purpose: Verify EECIV module and actuator circuit respond to sensor input.
1. KOEO or KOER; AUTO or DCV mode.
2. Select actuator on PIN SELECTOR A or B.
3. Create change for input device with switchbox or vehicle operation.
4. Observe change (response) in actuator signal, observe light.
5. Examples: Increase throttle (TP), observe SPOUT increase.
Move EGO switch to LEAN, observe SPOUT increase.
Turn on AIC at WOT, observe WAC light on and grounded.
CHECK VALUE
Purpose: Activate solenoid or relay from EECIV. Monitor and observe device..
1. KOEO/KOER; AUTO or DCV mode.
2. Select signal from PIN SELECTOR A or B.
3. Various units used, refer to Meter Function light.
CLICK-TESTING (RELA Y~/SOLENOIDS)

Purpose: Activate solenoid or relay from EECIV Monitor and observe device.
1. KOEO only; AUTO or DCV mode.
2. Select relay or solenoid signal on PIN SELECTOR A and correct ground on REFERENCE
PIN selector.
3. Insert switchbox into SELECTOR PIN jacks.
4. Push small red button to turn on relay or solenoid.
5. Listen for "click" of, device turning on, observe signal light turn on.

ALL RIGHTS RESERVED
18-28 EECIV Monitor Box: Intermittent Fault Diagnosis
APPENDIX: Methods of EEC-IV Monitor Measurements
COIL RESISTANCE (SOLENOIDS/RELAYS)

Purpose: Measure for correct resistance value of device.
1. Key Off only; Ohms mode.
2. Select signal from PIN SELECTOR A.
3. Select correct ground from REFERENCE PIN SELECTOR.
4. Select OHMS RANGE switch.
5. WIGGLE TEST will light and sound; press WIGGLE TEST RESET button
6. Manual Test Light should be blinking; value in ohms units.
EEC-IV INPUT CHECK (STO)
Purpose: Confirm that EEC-IV Processor set 'CHECK ENGINE LIGHT' for certain EEC-IV sensors
(refer to CHECK ENGINE Light Symptom Chart). .
1. KOEO; DCV mode.
2. Select sensor from PIN SELECTOR A.
3. Set REFERENCE PIN SELECTOR to SIG RTN.
4. Insert switchbox into SELECTOR PIN jacks.
5. Move AIM switch to KEY ON, ENGINE OFF position.
6. Push small red button on switch box and observe STO light turn on and beeper sound as
long as button is pressed.
7. Return AIM switch to OFF position.
HARNESS OPENS
Purpose: Check harness for open circuits.
1. Key Off; Ohms mode.
3. Disconnect sensor/actuator where signal is to .be checked.
4. Connect jumper wire from REFERENCE PIN jack (black) to signal pin on harness to be
tested.
5. Check for continuity - 0 ohms.
HARNESS SHORTS
Purpose: Check harness for short circuits (to ground or power).
1. Key Off; Ohms mode.
3. Set OHMS RANGE switch to 200K.
4. Disconnect sensor/actuator to be tested.
5. Optional: Disconnect EEC-IV processor (reconnect Monitor to EEC-IV harness).
6. Select various power or ground signals from REFERENCE PIN SELECTOR. Example:
VREF, SIG RTN, PWR GND.
7. Read resistance: 0 or low indicates a short, 10K or higher - no short.

ALL RIGHTS RESERVED
EECIV Monitor Box: 'Intermittent Fault Diagnosis 1829
APPENDIX: Methods of EEC,IV Monitor Measurements
OUTPUT STATE CHECK (SOLENOIDS/RELAYS)
Purpose: Exercise actuator devices after KOEO SelfTest.
1. KOEO; AUTO or DCV mode.
2.' Move AIM switch, to KEY ON ENGINE ON position and wait for output- codes (beeps) to
end.
3. Completely depress an'd release throttle - observe signal light turn on.
4. Completely depress and release throttle -light should turn off.
5.. Return AIM switch to OFF position.
WIGGLE TESTING (DCV OR OHMS)

, (
Purpose: Sensitive DeVor ohms testing f()r intermittent harness or device.
1. Key off only for Ohms Wiggle; KOEO or KOER .for DCV Wiggle.
2. Use DCV Wiggle for all actuators, power and ground signals, all sensors which use DCV
units in AUTO mode; all others use Ohms Wiggle.
3. Examples: Ohms Wiggle MAP, PIP, INJ; DCV Wiggle - TP, ECT, EVR. DCV Wiggle is
more sensitive than the Ohms Wiggle Test.
5. Select correct ground from REFERENCE PIN SELECTOR.
6. Tap components, flex harness and connectors.
7. Wiggle Test light and beeper will activate when change sensed.

ALL RIGHTS RESERVED
APPENDIX: Diagnostic Reference Value Sheets
1990 DIAGNOSTIC REFERENCE VALUE SHEETS
Passenger Cars Trucks

1.9L EFI HO 18-31 2.3L EFI OHC 18-47
1.9L CFI 18-32 2.9L EFI ~ 18-48
1.9L SEFI 18-33 3.0L EFI " 18-49
2.3L EFI OHC 18-34 4.0L EFI MA 18-50
2.3L EFI OHC MA 18-35 4.9L EFI 18-51
2.3L EFI HSC 18-36 5.0L EFI 18-52
2.5L CFI HO 18-37 5.8L EFI 18-53
2.9L EFI 18-38 7.5L EFI 18-54
3.0L EFI 18-39 7.3L DIESEL E40D 18-55
3.0L SEFI SHO " 18-40
3.8L SEFI AXOD 18-41
3.8L SEFI RWD 18042
3.8L SEFI SC 18-43
5.0L SEFI 18-44
5.0L SEFI 18-45
5.0L SEFI MA 18-46
NOTES
1. Diagnostic Reference Values are based on engine at norm~1 operating temperature
(ECT = .5 to .7v/180 to 220F).
2. KOEO and HOT IDLE test values are recorded with vehicle in PARK position (A/T) or
NEUTRAL position (MIT).
3. Before proceeding with Monitor TIMING checks, Monitor must be calibrated to BASE
TIMING. (Adjust BASE TIMING knob on Monitor.) BASE TIMING equals 10 degrees for all
vehicles. For EDIS vehicles (4.0L TRK) BASE TIMING is not adjustable.
4. Vehicles with manual transmission (MIT) use 3rd gear for their 30 MPH valves and 4th
gear for their 55 mph values. Vehicles with automatic transmission (A/T) use D for their
55 mph values.
5. Reference values shown in chart may 'differ between vehicles due to various factors:
component tolerances, driving conditions, weather, etc. These values were recorded at
approximately 600' altitude above sea level and ambient temperatures from 50 to 70
degrees F. Some EEC-IV devices, such as ACT, ECT and EDF are temperature dependent
and their values may vary greatly. Other values such as ISC-BPA and INJ are calibration
dependent and may vary also.

ALL RIGHTS RESERVED
1.9L
APPENDIX: Diagnostic Reference Values EFI
HO
CAR
ESCORT GTIEXP
SENSORSI Signal
INPUTS Pin #. KOEO Units HOT IDLE' 30 MPH 55 MPH Units
TP 47 1.0 DCV 1'.0 1.2 1.3-1.4 DCV

ECT 7 .6 DCV .6 .6 .6 DCV
VAT 25 2.5 DCV 3.5 3.6 3.8 DCV
BP 45 158 Hz 158 158 158 Hz
IDM 4 0 RPM 950-1050 2200-2300 2800-2900 RPM
PIP 56 0 RPM 950-1050 2200-2300 2800-2900 RPM
HEGO 29 0 DCV switching switching switching DCV
FPM 8 0 DCV VBAT VBAT VBAT DCV
ACC 10 0 DCV 0/VBAT0 .. 0 0 DCV
VAF 43 .3 DCV .9 2.0-2.3 2.4-2.7 DCV.
NGS/CES 30 0 DCV 0 5.0/00 5.0 DCV
STI 48 5.0 DCV 3.5-5.0' 3.5-5.0 3.5-5.0 DCV
ACTUATORSI .
OUTPUTS
INJ Bank 2 59 VBAT@ DCV 3.6-4.0 4.0-5.0 3.7-5.4 mS

STO 17 VBAT DCV VBAT VBAT VBAT DCV
WAC 54 0 DCV 8.0 8.0 8.0 DCV
ISC-BPA 21 VBAT DCV 12.0 10.0 9.0 DCV
FP .22 VBAT DCV .8 .8 .8 DCV
SPOUT 36 0 RPM 950-1050 2200-2300 2800-2900 RPM
CANP 32 VBAT DCV VBAT VBAT 0 DCV
MIL 53 0 DCV VBAT VBAT VBAT DCV
EGR SIO 35 VBAT DCV VBAT VBAT 0 DCV
OTHER
IGN TIMING TIMING 31-34 37-40 40-44 DEG
NOTES: CD A/C on.

Clutch pedal depressed.
Monitor in DCV manual mode.
Reference values shown may vary ..approxlmately 20 0k depending on op~ratlng
conditions and other factors. RPM values are axle and tire dependent.

ALL RIGHTS RESERVED
1.9L
APPENDIX: Diagnostic Reference Values CFI
CAR
ESCORT
SENSORS/ Signal
INPUTS Pin :# KOEO Units HOT IDLE 30 MPH 55 MPH Units
TP 47 1.0 DCV 1.0 1.2 1.5 DCV

PFE 27 3.2 DCV 3.2 3.4 1.8 DCV
ECT 7 .7 DCV .7 .7 .7 DCV
ACT 25 1.2 DCV 1.2 1.2 1.2 DCV
MAP 45 158 Hz 104 103-113 125-130 Hz
IDM 4 0 RPM 820-900 1450-1500 2650-2800 RPM
PIP 56 0 RPM 820-900 1450-1500 2650-2800 RPM
ACCS 10 0 DCV O/VBAT0) 0 0 DCV
NDS (A/T) 30 0 DCV 0 5.0 5.0 DCV
NGS (MIT) 30 0 DCV 0 5.0 5.0 DCV
ITS 28 9.3 DCV 10.5 0 0 DCV
STI 48 5.0 DCV 3.5-5.0 3.5-5.0 3.5-5.0 DCV
ACTUATORS/
OUTPUTS
INJ 58 VBAT DCV 1.5 1.7-2.0 2.2-2.6 mS

EVR 52 VBAT DCV 0 0 40-50 %
STO/MIL 17 .6 DCV VBAT VBAT VBAT DCV
WAC 54 0 DCV 0/7.40) 0 0 DCV
ISC+ 21 0 DCV 0 0 0 DCV
FP 22 VBAT DCV .9 .9 .9 DCV
SPOUT 36 0 RPM 820-900 1450-1500 2650-2800 RPM
SIL (MIT) 51 VBAT DCV VBAT VBAT VBAT DCV
CANP 32 VBAT DCV VBAT VBAT 0-6.0 DCV
OTHER
NOTES: CD- A/C on.

- Monitor in DCV manual mode.
HEGO in 'switching' mode ranges from .2 to .9" DCV.
Reference values shown may vary 20% depending on operating conditions
, and other factors. RPM values are axle and tire dependent.

ALL RIGHTS RESERVED
EECIV Monitor Box: Intermittent. Fault Diagnosis 1833
1.9L
AfPENDIX: Diagnostic Reference Values. SEFI
CAR
SENSORSI Signal
.. INPUTS Pin :# KOEO Units HOT IDLE 30 MPH 55 MPH Units
TP 47 DCV DCV
MAF 50 DCV DCV
PFE 27 DCV DCV
ECT 7 DCV DCV
ACT 25 DCV DCV
IDM 4 RPM RPM
CID+ 41 DCV DCV
PIP 56 RPM RPM
HEGO 29 DCV DCV
FPM 19 DCV DCV
, ACC 10 DCV CD DCV
VSS+ 3 MPH MPH
OCTADJ1 43 DCV DCV
OCTADJ2 34 DCV DCV
NDS (AID 30 DCV DCV
NGS/CES (MID 30 DCV DCV
STI 48 DCV DCV
ACTUATORSI
OUTPUTS
INJ 4 13 DCV mS
INJ 2 59 DCV mS
INJ 1 58 DCV mS
EVR 33 DCV %
STO/MIL 17 DCV DCV
HEDF 31 DCV DCV
WAC 54 DCV DCV
ISC-BPA 21 DCV , DCV
FP 22 DCV DCV
INJ 3 12 DCV mS
SAW 36 RPM RPM .
SIL(M/D 53 DCV DCV

EDF 35 DCV DCV
OTHER
IGN TIMING TIMING DEG
NOTES: CD - Ale on.

- Clutch pedal depressed.
.- Monitor in DCV manual mode.
HEGO in 'switching' mode ranges from .2 to .9 DCV.
and other factors. RPM values are axle and tire dependent.
1.9L SEFI IS 1990.5 VEHICLE, VALUES ARE UNAVAILABLE.

ALL RIGHTS RESERVED
2.3L
OHC
CAR
MUSTANG
SENSORS/ Signal
INPUTS Pin # KOEO Units HOT IDLE 30 MPH 55 MPH Units
TP 47 .8 DCV .8 1.0 1.3 DCV
EVP 27 .4 DCV .4 .6 1.4-2.4 DCV
ECT 7 .8 DCV .8 .8 .8 DCV
ACT 25 1.2 DCV 1.6 1.8 1.6 DCV
MAP 45 158 Hz 102-104 106-109 125-130 Hz
IDM 4 0 RPM 850-900 1650-1750 2700-2800 RPM
PIP 56 0 RPM 850-900 1650-1750 2700-2800 RPM
KS 23 2.5 DCV 2.5 2.5 2.5 DCV
BOO 2 0 DCV O/VBATCD 0 0 DCV
ACC 10 0 DCV 0/VBAT0 0 0 DCV
PSPS 3 0 DCV 0/10.0 turn 0 0 DCV
ACD 24 0 DCV 0/VBAT0 0 0 DCV
NDS (AfT) 30 0 DCV 0 5.0 5.0 DCV
NGSfCES (MfT) 30 0 DCV 0 5.0/0 5.0 DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCY
ACTUATORS/
OUTPUTS
INJ Bank 2 59 VBAT0 DCV 3.7-4.4 5.2-6.0 5.6-7.4 mS.

INJ Bank 1 58 VBAT0 DCV 3.7-4.4 5.2-6.0 5.6-7.4 mS
EGRC 52 VBAT0 DCV 0 0 0 %
EGRV 33 VBAT0 DCV 0 98 98 %
STOfMIL 17 .7 DCV VBAT VBAT VBAT DCV
WAC 54 0 DCV 0 0 0 DCV
ISC-BPA 21 VBAT DCV 9.0-9.7 9.0-9.3 8.8 DCY
FP 22 VBAT DCV .9 .9 .9 DCY
SPOUT 36 0 RPM 850-900 1650-1750 2700-2800 RPM
CCO (AfT) 53 VBAT DCV VBAT .7 .7 DCV
OTHER
IGN TIMING TIMING ' 16-22 22-23 32-35 DEG
NOTES: CD - Brake pedal depressed.

0- A/C on.
@) - Monitor in DCV manual mode.
Reference values shown may vary 200/0 depending on operating conditions

ALL RIGHTS RESERVED
EECIV Monitor Box:- 'Intermittent Fault Diagnosis 1835
2.3L
!\~PENDIX: Diagnostic Reference Values EFI
OHC'MA
CAR
MUSTANG (CALIFORNIA ONLY)
SENSORS/ Signal
INPUTS Pin # KOEO Unl.ts HOT IDLE 30 MPH 55 MPH Units
MAF' 14 0 DCV .6 1.3-1.5 1.8-2.2 DCV
TP 47 1.0 DCV 1.0 1.2-.1.3 1.5 OCV
EVP - 27 .4 DCV .4 . -.4 .4-3.0 OCV
ECT 7 .8 - OCV .8 .8 .8 OCV
ACT 25 2.1 OCV 2.4 2.6 2.9 OCV
BP 45 157 Hz 157 157 157 Hz
10M 4 0 RPM 830-880 1400-1450. 2750-2800 RPM
PIP 56 0 RPM 830-880 1400-1450 2750-2800 RPM
KS 23 . 2.5 DCV 2.5 2.5 2.5 DCV
HEGO 29 0 DCV sWitching switching sWitching OCV
BOO 2 0 DCV O/VBAT<D ' 0 0 DCV
ACCS 10 0 OCV 0/VBAT0 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
PSPS 24 ' 0 DCV', 0/10.0 turn 0 0 OCV
ACO 43 0 DCV 0/VBAT0 0 0 DCV
NDS (A/T) 30 .7 DCV .7 5.0 5.0 DCV
NGS/CES (M/T) 30 0 DCV 0 5.0/0@ 5.0 DCV
STI - 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORSI
OUTPUTS
INJ Bank 2 59 VBAT0 DCV 3.6-3.7 4.56.0 6.0-7.2 mS
. INJ Bank 1. 58 VBAT0 DCV 3.6-3.7 4.5-6.0 6.0-7.2 mS
5S 3/4 (A/T) 52 VBAT DCV VBAT .3 .3 DCV
EVR 33 VB AT0 DCV 0 - 0 0-50 0/0
STO/MIL 17 0 OCV VBAT VBAT VBAT DCV

CANP 31 VBAT OCV YBAT 6.0-YBAT .2 DCV
WAC 54 0 OCV 0 0 0 OCV
ISC-BPA 21 VBAT DCV" 10.1 9.8 9.2-9.6 DCV
FP 22 VBAT OCV .1 .1 .1 DCV
SPOUT, 36 0 RPM 830-880 1400-1450 2750-2800 RPM
. CGO (A/T) 53 VBAT DCV' YBAT VBAT .3 OCV
OTHER
IGN TIMING TIMING 13-14 18 22-25 OEG
NOTES: 6) - Brake pedal depressed.

- AIC on.
-. Clutch pedal depressed.
@) - Monitor In DCV manual mode.
,-

and other factors. RI:M values. are axle and tire dependent.

ALL RIGHTS RESERVED
2.3L
APPENIlIX: Diagnostic Reference Values EFI
HSC
CAR
TEMPO/TOPAZ
SENSORS/ Signal
TP 47 .9 DCV .9 1.1-1.3 1.3-1.5 DCV

PFE 27 3.2 DCV 3.2 3.4 2.5-3.5 DCV
ECT 7 .7 DCV .7 .7 .7 DCV
ACT 25 1.2 DCV 1.2 1.7 2.0-2.4 DCV
MAP 45 158 Hz 107 107-112 120-128 Hz
IDM 4 0 RPM 840-880 1600-2000 2650-2900 RPM
PIP 56 0 RPM 840-880 . 1600-2000 2650-2900 RPM
FPM 8 0 DCV VBAT VBAl VBAT DCV
ACCS 10 0 DCV O/VBATCD 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
ACD 43 0 DCV O/VBATCD 0 0 DCV
NDS (A/T) 30 .6 DCV .6 VBAT VBAT DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORS/
OUTPUTS

EVR 33 VBAT@ DCV 0 ~ 40-50 %
CANP 31 VBAT DCV VBAT .2-VBAT .2 ' DCV
WAC 54 0 DCV 0/7.S(]) 0 . 0 DCV
ISC-BPA 21 VBAT DCV 9.9 8.5-9.0 8.5 DCV
SPOUT 36 0 RPM 840-880 1600-2000 2650-2900 RPM
S/L (MIn 53 VBAl DCV VBAT VBAT VBAT DCV
OTHER
NOTES: 0 - A/C on.

- Monitor In DCV manual mode.

ALL RIGHTS RESERVED
2.5L
APPENDIX: Diagnostic Reference Values CFI
HO
CAR
TAURUS
SENSORS/ Signal
TP 47 1.4 DCV 1.0 1.2 1.4 DCV

SCCS 50 6.7 DCV 6.7 6.7 6.7 DCV
EVP 27 .4 DCV .4 1.3 3.2 DCV
ECT 7 .7 DCV .7 .7 .7 DCV
ACT 25 .8 DCV .7 1.0 1.0 DCV
MAP 45 158 Hz . 105 110 123 Hz
10M 4 0 RRM 820-850 1475-1550 2550-2650 RPM
PIP 56 0 RPM 820-850 1475-1550 2550-2650 RPM
HEGO 29 0 DCV sWitching switching switching DCV
BOO 2 0 DCV VBATCD 0 0 DCV
ACCS 10 0 DCV VBAT@ 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
ITS 24 VBAT DCV VBAT 0 0 DCV
NOS 30 0 DCV 0 VBAT VBAT DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORS/
.OUTPUTS
INJ 58 VBAT@ DCV 1.6-1.7 2.0-2.1 2.5-2.7 mS

HEDF 52 VBAT DCV VBAT VBAT VBAT DCV
EVR 33 VBAT@ DCV 0 40 50 %
CANP 31 VBAT DCV VBAT VBAT .2 DCV
WAC 54 0 DCV 0/7.7@ 0 0 DCV
ISC+ 21 0 DCV 0 0 0 DCV
SCVAC 42 VBAT@ DCV 0 0 0 %
SPOUT 36 0 RPM 820-850 1475-1550 2550-2650 RPM
SCVNT 35, VBAT@ DCV 0 98 98 %
EDF 55 0 DCV 8.5 0 0 DCV
OTHER
NOTES: CD Brake pedal depressed.

A/C on.
Monitor in DCV manual mode.
HEGO in 'switching' mode ranges from' .2 to .9 DCV. Speed Control (SCCS,
SCVAC, SCVNT) is applied for 30 MPH and 55 MPH.
Reference values shown may vary approximately 20% depending on operating
conditions and other factors. RPM values are axle and tire dependent.

ALL RIGHTS RESERVED
2.9L
CAR
SCORPIO
SENSORSI Signal
TP 47 DCV DCV
ECT 7 DCV DCV
BOO 18 DCV CD DCV
ACT 25 DCV DCV
MAP 45 Hz Hz
PIP 56 RPM RPM
OCT ADJ 23 DCV DCV
HEGO 29 DCV DCV
KDS 19 DCV DCV
ACC 10 DCV DCV
VSS+ 3 MPH MPH
HEGO-2 43 DCV DCV
NDS 30 DCV DCV
IDLE ADJ 28 DCV DCV
STI 48 DCV DCV
ACTUATORSI
OUTPUTS
SS 3/4 15 DCV DCV

INJ Bank 2 59 DCV mS
INJ Bank 1 58 DCV mS
STO 17 DCV DCV
CANP 31 DCV DCV
WAC 54 DCV DCV
ISC-BPA 21 DCV DCV
FP 22 DCV DCV
SPOUT 36 RPM RPM
CCO 53 DCV DCV
OTHER
IGN TIMING TIMING DEG

0- A/C on.
2.9L EFI VALUES ARE UNAVAILABLE.

ALL RIGHTS RESERVED
3.0L
APPENDIX: Diagnostic Reference', Values EFI
CAR
TAURUS/SABLE/PROBE
SENSORS/ Signal
INPUTS Pin :# KOEO Units HOT IDLE 30 MPH 55 MPH . Units
TP 47 .8 DCV .8 .9 1.2~1.4 -DCV
SCCS 50 6.7 DCV 6.7 6.7 6.7 DCV
PFE 27 3.2 "DCV 3.2 3.4 3.5-3.8 DCV
ECT' 7 .6 DCV .6 .6 .6 DCV
. THS 4/3 (AXOD) 25 10.0 DCV 11.0 0 0 DCV
ACT 25 ' 1.5 DCV 2.0-2.5 2.0-3.0 2.2-3.2 DCV
MAP 45 158 Hz 108-110 110-114 118-120 Hz
IDM 4' 0 RPM 750-850 1300-1500 2500-2800 RPM
PIP 56 0 RPM 750-850 1300-1500 2500-2800 RPM
THS3/2(AXOD) 19 10.0 DCV 11.0 - 0 0 DCV
BOO 2 0 DCV 0/VBAT0 0 0 DCV
FPM 8 0 DCV 4
VBAT VBAT VBAT DCV
VSS+ 3 0 MPH 0 30 : 55 MPH
NDS (AfT) 30 0 DCV' 0 VBAT VBAT DCV
NPS (AXOD) '30 VBAT DCV VBAT VBAT VBAT DCV
NGS/CES (MIT) 30 0 DCV 0 5.0/0@) 5.0 DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORS/
OUTPUTS
INJ Bank 2 59 VBAT@) DCV 05.8-6.1 7.0-8:0 7.5-10.0' mS
INJ Bank f 58 VBAT@) DCV 5.8-6.1 7.0-8.0 7.5-10.0 mS
EVR 33 VBAT@) DCV 0 0 0-40 0/0
STO/MIL 17 .6 DCV VBAT VBAT ~

VBAT DCV
CANP 31 VBAT DCV VBAT 9.o-VBAT .2-5.0 DCV
WAC 54 0 DCV 017.50 0 0 DCV
ISC-BPA 21' VBAT DCV 11.0 8.5-9.0 7.5-8.0 DCV
SCVAC 42 VBAT@) DCV 0 0 '0 0/0

2500-2800 RPM
'0
SPOUT 36 0 RPM 750-850 1300-1500

LUS (AXOD) 53 VBAT DCV VBAT .7 .7 DCV
SCVNT 35 VBAT@) DCV 0 97 97' '%
EDF 55 0' DCV 0 - 0/8.0 0/8.0 DCV
OTHER
NOTES: 0- Brake pedal depressed.

0 - A/C on.
@)- Clutch pedal depressed.
HEGO In 'switching' mode ranges trom .2 to .9 DCV. Speed Control (SCCS, SCVAC, SCVNT) is applied for
30 mph and 55 mph.
Reference values shown may vary 20% depending on operating conditions and other factors. RPM values
are axle and tire dependent.

ALL RIGHTS RESERVED
1840 EEC-IV Monitor Box: Intermittent Fault Diagnosis
3.0L
ApPENDIX: Diagnostic Reference Values SEFI
SHO
CAR
TAURUS SHO
SENSORSI Sig.
INPUTS Pin 1/ KOEO Units HOT IDLE 30 MPH 55 MPH Units
TP 47 .7 DCV .7 1.0 1.1 DCV

MAF 50 0 DCV .7 1.2-1.3 1.8-2.0 DCV
PFE 27 3.3 DCV 3.3 3.5 3.5 DCV
ECT 7 .6 DCV .6 .6 .6 DCV
ACT 25 2.5 DCV 3.0 3.3 3.4 DCV
BP 45 157 Hz 157 157 157 Hz
IDM 4 0 RPM 800-850 2000-2100 2750-2800 RPM
PIP 56 O. RPM 800-850 2200-2100 2250-2800 RPM
KS 23 2.5 DCV 2.5 2.5 2.5 DCV
HEGO-R 29 0 DCV switching switching switching DCY
FPM . 19 0 DCV 10.4 10.4 10.4 DCY
ACCS 10. 0 DCV O/VBAT@) 0 0 DCY
VSS+ 3 0 MPH 0 30 55 MPH
CID 24 VBAT DCV 5.0-7.0 6.0-6.5 6.0-6.5 DCV
HEGO-l 43 0 DCV switching .swltchlng switching DCY
CES 30 4.7 DCV 4.7 4.710@ 4.7 DCY
SCCS 28 6.7 DCV 6.7 6.7 6.7 DCY
BOO 5 0 DCY O/VBAT<D 0 0 DCY
STI 48 5.0 DCV 5.0 5.0 5.0 DCY
ACTUATORSI
OUTPUTS
INJ 4 13 VBAT0 DCV 4.0-4.2 4.0-5.0 5.0-5.5 mS

INJ 6 15 VBAT0 DCV 4.0-4.2 4.0-5.0 5.0-5.5 mS
INJ 5 14 VBAT0 DCV 4.0-4.2 4.0-5.0 5.0-5.5 mS
INJ 2 59 VBAT0 DCV 4.0-4.2 4.0-5.0 5.0-5.5 mS
INJ 1 58 VBAT0 DCV 4.0-4.2 4.0-5.0 5.0-5.5 mS
EVR 33 VBAT0 DCV 0 0 0 0/0
STO/Mll 17 .6 DCV VBAT . VBAT VBAT DCY

CANP 31 VBAT DCV VBAT 0.6.0 .2 DCV
WAC 54 0 DCV 017.7@) 0 0 DCY
ISCBPA 21 VBAT DCV 9.4 8.3-8.5 8.0 DCY
HFP 41 VBAT DCV VBAT VBAT VBAT DCV
FP 22 VBAT DCV .8 .8 .8 DCY
INJ 3 12 VBAT0 DCV 4.0-4.2 4.0-5.0 5.0-5.5 mS
SPOUT 36 _ 0 RPM 8OD-850 2000-2100 2750-2800 RPM
lAC 32 .7 DCV .7 .7 .7 DCY
SCVAC 51 VBAT0 DCV 0 0 0 0/0
SCVNT 35 VBAT0 DCV 0 98 98 %

EDF 55 0 DCV 0 0 0 DCV
OTHER

o A/C on.
- Clutch petal depreaaed.
o Monitor In DCY manual mode.
HEGO In 'switching' mode ranges from .2 to .9 DCY.
Speed control (SCCS, SCVAC, SCVNT) is applied for 30 MPH and 55 MPH.
Reference values shown may vary approximately 20% depending on operating conditions and other
factors. RPM values are axle and tire dependent.

ALL RIGHTS RESERVED
3.8L
APPENDIX: Diagnostic Reference Values SEFI
AXOD
CAR
TAURUS/SABLE/CONTINENTALITAURUS POLICE
SENSORSI Signal
INPUTS Pin :/I KOEO Units HOT IDLE 30 MPH 55 MPH Units
TP 47 .9 DCV .9 1.1 1.3-1.4 DCV
PFE 27 3.2 DCV 3.2 3.4 3.0-3.3 DCV
ECT 7 .6 DCV .6 .6 .6 DCV
THS 4/3 18 9.5 DCV 11.0 0 0 DCV
ACT 25 .9 DCV .9 1.8 1.5-1.8 DCV
MAP 45 158 Hz 105 107-108 118-121 Hz
10M 4 0 RPM 700-730 1450-1600 2500-2600 RPM
PIP 56 0 RPM 700-730 1450-1600 RPM.
HEGO-R 29 0 DCV switching switching 2500-2600 DCV
THS 3/2 19 9.5 DCV 11.0 0 0 DCV
ACC 10 0 DCV O/VBAT@ 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
HEGO-L 43 0 DCV switching switching switching DCV
NPS 30 4.6 DCV 4.6 0 0 DCV
SCCS 28 6.7 DCV 6.7 6.7 6.7 DCV
BOO 5 0 DCV. 0/V8ATQ) 0 0 DCV
STI 48 5.0 DCV 5.0 5.0
. 5.0 DCV
ACTUATORS/
OUTPUTS
INJ 4 13 VeAT@) DCV 6.0-6.8 7.0-8.0 9.0-11.0 mS

INJ 6 15 VeAT@) DCV 6.0-6.8 7.0-8.0 9.0-11.0 mS
INJ 5 14 VBAT@) DCV 6.0-6.8 7.0-8.0 9.0-11.0 mS
INJ 2 59 VeAT@) DCV 6.0-6.8 7.0-8.0 9.0-11.0 mS
INJ 1 58 VBAT@) DCV _ 6.0-6.8 7.0-8.0 9.0-11.0 mS
EVA 33 VeAT@) DCV 0 0 40 %
STO/MIL 17 .7 DCV veAT VBAT VBAT DCV
CANP 31 VBAT DCV veAT VBAT .2 DCV
WAC 54 0 DCV 01750 0 0 DCV
ISC-BPA 21 veAT DCV 10.0 8.2-9.5 7.0-9.0 DCV
HEDF 41 VBAT DCV VBAT veAT VBAT DCV
INJ 3 12 veAT@ DCV 6.0-6.8 7.0-8.0 9.0-11.0 mS
SPOUT 36 0 RPM 700-730 1450-1600 2500-2600 RPM
ACL 32 5.0 DCV 5.0 5.0 5.0 DCV
SCVAC 51 VeAT@ DCV 0 0 0 0/0
LUS 53 veAT DCV veAT VBAT .9 DCV

SCVNT 35 VBAT@) DCV 0 98 98 %
OTHER
IGN TIMING TIMING 14-16 3435 35-40 DEG
NOTES: Q) - Brake pedal depressed.

@- A/C on.
HEGO In 'switching' mode ranges from .2 to ~9 DCV.
Reference values shown may vary 20% depending on operating conditions and other factors. RPM values
are axle and tire dependent.

ALL RIGHTS RESERVED
3.8L
RWD
CAR
THUNDERBIRD/COUGAR
SENSORS/ Signal
INPUTS Pin # KOEO Units HOT IDLE 30 MPH 55 MPH Units.
TP 47 .9 DCV .9 1.0 1.2-1.3 DCV

PFE 27 3.2 DCV 3.2 3.4 3.6 DCV
ECT 7 .6 DCV .6 .6 .6 DCV
ACT 25 .9 DCV 1.0 2.0 1.6-2.0 DCV
MAP 45 157 Hz 102 105-107 110-115 Hz
10M 4 0 RPM 700-750 1250-1300 2200-2300 APM
PIP 56 0 APM 700-750 1250-1300 2200-2300 APM
BOO 5 0 DCV O/VBATG) 0 0 DCV
HEGO-A 29 0 DCV switching switching switching DCV
VSS+ 3 0 MPH 0 30 55 MPH
HEGO-L 43 0 DCV switching switching switching DCV
ACCS 10 0 DeV O/VBAT@) 0 0 DCV
SCCS 28 6.7 DCV 6.7 6.7 6.7 DCV
NOS 30 0 DCV 0 4.6 4.6 DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORS/
OUTPUTS
INJ.1 58 VBAT@ DCV 6.0-6.2 7.5-9.0 8.0-9.5 mS

INJ 2 59 'VBAT@ DCV 6.0-6.2 7.5-9.0 8.0-9.5 mS
INJ 3 12 VBAT@ DCV 6.0-6.2 7.5-9.0 8.0-9.5 mS
INJ 4 13 VBAT@ DCV 6.0-6.2 7.5-9.0 8.0-9.5 mS
INJ 5 14 VBAT@ DCV 6.0-6.2 7.5-9.0 8.0-9.5 mS
INJ 6 15 VBAT@ DCV 6.0-6.2 7.5-9.0 8.0-9.5 mS
EVA 33 VBAT@ DCV 0 0 40 %
CANP 31 VBAT DCV VBAT VBAT .2-5.0 DCV
WAC 54 0 DCV 0 0 0 DCV
FP 22 VBAT DCV 10.2-10.5 8.8-9.4 6.0-8.0 DCV
SPOUT 36 0 APM 700-750 1250-1300 2200-2300 RPM
SCVNT 35 VBAT@ DCV 0 98 98 %
OTHER
NOTES: G) - Brake pedal depressed.

@) - A/C on.
@ - Monitor In DCV manual mode.
HEGO In 'switching' mode ranges from .2 to .9 DCV.
Speed Control (SCCS, SCVAC, SCVNT) Is applied for 30 mph and 55 mph.
Reference values shown may vary approximately 20% depending on operating conditions and
other factors. RPM values are axle and tire dependent.

ALL RIGHTS RESERVED
3.8L
APPENDIX: Diagnostic Reference Values' SEFI
SC
CAR
THUNDERBIRD/COUGAR
SENSORS/ Signal
TP .47 .8 DCV .8 .9-1.0 1.1-1.2 DCV

MAF 50 0 DCV .7 1.2-1.3 1.8-2.0 DCV
PFE 27 3.2 DCV 3.2 3.4 3.6-3.7 DCV
ECT 7 .6 DCV .6 .6 .6 DCV
ACT 25 2.0 DCV 2.5 3.0 3.0 DCV
BP 45 158 Hz 158 158 158 Hz
10M 4 0 RPM 770-800 1500-1550 1800-1900 . RPM
PIP 56 0 RPM 770-800 1500-1550 1800-1900 RPM
KS 23 2.5 DCV 2.5 2.5 2.5 DCV
HEGOR 29 0 DCV switching switching switching DCV
VSS+ 3 0 MPH 0 30 55 MPH
CID 24 O/VBAT DCV 5.0-7.0 5.5-6.0 5.5-6.0- DCV
HEGOL 43 0 DCV switching switching switching DCV
NGS/CES (MIT) 30 0 DCV 0 4.8/00 4.8 DCV
SCCS 28 6.7 DCV 6.7 6.7 6.7 DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORS/
OUTPUTS
INJ 4 13 VABT0 DCV 4.0-4.4 4.5-5.0 5.7-7.0 mS
INJ 6 15 VBAT0 DCV 4.0-4.4 . 4.5-5.0 5.7-7.0 mS
INJ 5 14 VBAT0 DCV 4.0-4.4 4.5-5.0 5.7-7.0 mS
INJ 2 59 VBAT0 DCV 4.0-4.4 4.5-5.0 5.7-7.0 mS
INJ 1 58 VBAT0 DCV 4.0-4.4 4.5-5.0 5.7-7.0 mS
EVR 33 VBAT0 DCV 0 0 40 0/0
%
SBS 38 VBAT0 DCV 0 0 0
CANP 31 VBAT DCV VBAT VBAT 6.0-8.5 DCV
WAC 54 0 DCV 01750 0 0 DCV
ISCBPA 21 VBAT DC.v 9.0-9.4 7.6-8.0 7.5 DCV
INJ 3 12 VBAT0 DCV 4.0-4.4 4.5-5.0 5.7-7.0 mS
SPOUT 36 0 RPM 770-800 1500-1550 1800-1900 RPM
ACL 32 5.0 DCV 5.0 5.0 5.0 DCV
%
SCVAC 51 VBAT0 DCV 0 0 0
SIL (MIT) 53 1.7 DCV VBAT VBAT VBAT DCV
SCVNT 35 VBAT DCV 0 98 98 %
OTHER
NOTES: CD Brake pedal d,pressed. ..

A/C on.
Clutch pedal depressed.
o Monitor In DCV Manual Mode.
Speed Control (SCCS, SCVAC, SCVNT) is applied for 30 MPH and 55 MPH.
Reference values shown may vary approximately 20% depending on operating conditions and other

ALL RIGHTS RESERVED
5.0L
CAR
MARK VII
SENSORSI Signal
INPUTS ,Pin #: KOEO Units HOT IDLE 30 MPH 55 MPH Units
TP 47 .8 DCV .8 1.0-1.1 1.2-1.3 DCV

SCCS 50 6.7 DCV 6.7 6.7 6.7 DCV
EVP 27 .3 DCV .3 .3 .8-1.5 DCV
ECT 7 .7 DCV .7 .7 .7 DCV
ACT 25 .9 DCV .9 1.5 1.6 DCV
MAP 45 157 Hz 107-110 105-112 110-118 Hz
IDM 4 0 RPM 690-720 1330-1360 2350-2450 RPM
PIP 56 0 RPM 690-720 1330-1360 2350-2450 RPM
HEGO-R 29 0 DCV switching sWitching switching DCV
ACCS 10 0 DCV O/VBAT 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
HEGO L 43 0 DCV switching sWitching switching DCV
NDS 30 0 DCV 0 VBAT VBAT DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORSI
OUTPUTS
INJ 4 13 VBAT@ DCV 4.7-5.0 5.0-6.0. 6.4-7.8 mS

INJ 6 15 VBAT@ DCV 4.7-5.0 5.0-6.0 6.4-7.8 mS
INJ 5 14 VBAT@ DCV 4.7-5.0 5.0-6.0 6.4-7.8 mS
INJ 2 59 VBAT@ DCV 4.7-5.0 5.0-6.0 6.4-7.8 mS
INJ 1 58 VBAT@ DCV 4.7-5.0 5.0-6.0 6.4-7.8 mS
INJ 8 52 VBAl@ DCV 4.7-5.0 5.0-6.0 6.4-7.8 mS
EVR 33 VBAT@ DCV 0 0 0 %
STO/MIL 17 .7 DCV VBAl VBAT VBAl DCV
CANP 31 VBAl DCV VBAT 6.0-7.0 6.0-7.0 DCV
WAC 54 0 DCV O/VBAT 0 0 DCV
ISC-BPA 21 VBAl DCV 8.8 7.0-8.2 6.8-7.8 DCV
INJ 7 42 VBAl@ DCV 4.7-5.0 5.0-6.0 6.4-7.8 mS
FP 22 VBAl DCV .9 .9 .9 DCV
INJ 3 12 VBAl@ DCV 4.7-5.0 5.0-6.0 6.4-7.8 mS
SPOUT 36 0 RPM 690-720 1330-1360 2350-2450 RPM
AM 1 51 VBAl DCV 0 0 0 DCV
AM 2 11 VBAT DCV VBAT VBAT VBAT DCV
SCVNT 35 VBAT@ DCV 0 98 98 %
OTHER

A/C on.
@ Monitor In DCV manual mode.
Speed Control (SCCS. SCVAC. SCVNT) is applied for 30 mph and 55 mph.
Reference values shown may vary approximately 20% depending on operating conditions and
other factors.

ALL RIGHTS RESERVED
EEC..IV Monitor Box: Intermittent Fault Diagnosis 18..45
5.0L
CAR
CROWN VICTORIA/GRAND MARQUIS/LINCOLN TOWN CAR
SENSORSI Signal
TP 47 1.0 DeV 1.0 . 1.1-1.2 1.3-1.4 'De\;

MAF@ 50 0 Dev 1.0 1.5-1.7 2.0-2.5 Dev
EVP 27 .4 Dev ,.4 ' . .7-1.0 2.0-3.0 Dev
EeT 7 .6 Dev .6 .6 .6 Dev
AeT 25 .9 Dev .9 1.0-1.5 1.5-1.8 Dev
MAP 45 158 Hz 105 105 123-125 Hz
BP@ 45 158 Hz 158 . 158 158 Hz
IDM 4 0 APM 700-750 1200-1300 1450-1550 APM
PIP 56 0 APM 700-750 1200-1300 1450-1550 APM
HEGOA 29 0 DeV switching switching .switching DeV
FPM 19 0 DeV VBAT VBAT VBAT DeV
BOO 2 0 DeV 0/VBAT0 0 0 DeV
AeeS 10 0 DeV 0/VBAT0 0 0 DeV
VSS+ 3 0 MPH 0 30 55 MPH
HEGO-L 43 0 DeV switching switching switching DeV
NDS 30 0 DeV 0 VBAT@ VBAT@ DeV
STI 48 5.0 DeV 5.0 5.0 5.0 DeV
ACTUATORSI
..
OUTPUTS
INJ 4 13 VBAT0 DeV 5.7-6.2 6.4-8.0 8.0-10.0 mS

INJ 6 15 VBAT0' DeV 5.7-6.2 6.4-8.0 8.0-10.0 mS
INJ 5 14 V8AT0 DeV 5.7-6.2 6.4-8.0 8.0-10.0 mS
INJ 2 59 VBAT0 DeV 5.7-6.2 6.4-8.0 8.0-10.0 mS
INJ 1 58 VBAT0 DeV 5.7~6.2 6.4-8.0 8.0-10.0 mS
INJ 8 52 V8AT0 DeV 5.7-6.2 6.4-8.0 8.0-10.0 mS
EVA 33 VBAT DeV 0 40 4D-60 0/0
AM1 38 VBAT DeV 0 0 VBAT DeV

STO/MIL 17 .6 DeV VBAT VBAT VBAT DeV
eANP 31 VBAT DeV VBAT .2-6.0 .2 DeV
WAe 54 0 DeV 0/VBAT0 0 0 DeV
ISe-BPA 21 VBAT DeV 10.0-11.5 9.0-9.5 7.5-8.5 DeV
INJ 7 42 VBAT0 DeV 5.7-6.2 6.4-8.0 .8.0-10.0 mS
FP 22 VBAT DeV .9 .9 .9 DeV
INJ 3 12 VBAT0 DeV 5.7-6.2 6.4-8.0 8.0-10.0 mS
SPOUT 36 0 APM 700-750 1200-1300 1450-1550 APM
AM2 32 VBAT DeV VBAT VBAT VBAT DeV
SeVAe 51 VBAT 0 Dev 0 0 0 %'
SeVNT 35 VBAT 0 Dev 0 98 98 %
OTHER
NOTES: Q) - Brake pedal depressed.

- A/C on.
- MA Vehicles only; NOS value for MA vehicles is 5.0 DCV.
Speed Control (SCCS,. SCVAC, SCVNn Is applied 30 mph and 55 mph.
Reference values shown may vary 20% depending on operating conditions and other factors. RPM
values are axle and tire dependent.

ALL RIGHTS RESERVED
5.0L
MA
CAR
MUSTANG
SENSORSI Signal
INPUTS Pin :/I KOEO Units HOT IDLE 30 MPH 55 MPH Units
TP 47 .9 DCV .9 1.0 1.2-1.3 DCV

MAF 50 f20 DCV .8 1.4-1.7 2.0 DCV
EVP 27 .4 DCV .4 .4 1.0 DCV
ECT 7 .6 DCV .6 .6 .6 DCV
ACT 25 .9 DCV .9 1.1 1.4 DCV
BP 45 158 Hz 158 158 158 Hz
IDM 4 0 RPM 670-700 1400-1500 . 2100-2500 RPM
PIP 56 0 RPM 670-700 1400-1500 2100-2500 RPM
HEGOR 29 0 DCV switching sWitching switching DCV
ACCS 10 0 DCV O/VBAT@ 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
HEGO-l 43 0 DCV switching switching switching DCV
NDS (AfT) 30 0 DCV 0 5.0 5.0 DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORSI
OUTPUTS
INJ 4 13 VBAT0 DCV 4.9-5.2 4.0-6.0 6.8-6.9 mS
INJ 6 15 VB AT0 DCV 4.9-5.2 4.0-6.0 6.8-6.9 mS
INJ 5 14 VBAT0 DCV 4.9-5.2 4.0-6.0 6.8-6.9 mS
INJ 2 59 VB AT0 DCV 4.9-5.2 4.0-6.0 6.8-6.9 mS
INJ 1 58 VBAT0 DCV 4.9-5.2 4.0-6.0 6.8-6.9 mS
INJ 8 52 VBAT0 DCV 4.9-5.2 4.0-6.0 6.8-6.9 mS
EVR 33 VBAT DCV 0 0 50-60 %
AM1 38 VBAT DCV 0 0 0 DCV
STO/Mll 17 .6 DCV VBAT VBAT VBAT DCV
CANP 31 VBAT DCV VBAT VBAT 9.0-VBAT DCV
WAC 54 , 0 DCV O/VBAT@ 0 0 DCV
ISC-BPA 21 VBAT DCV 9.0-10.0 7.5-7.9 6.0-7.2 DCV
INJ 7 42 VBAT0 DCV 4.9-5.2 4.0-6.0 6.8-6.9 mS
INJ 3 12 VBAT0 DCV 4.9-5.2 4.0-6.0 6.8-6.9 mS
SPOUT 36 0 RPM 670-700 1400-1500 2100-2500 RPM
AM2 32 VBAT DCV VBAT VBAT VBAT . DCV
OTHER
IGN TIMING TIMING 20 35-38 40 DEG
NOTES: <D - Brake pedal depressed.

0- A/C on.
@) - Monitor In DCY manual mode.
HEGO In 'switching' mode ranges from .2 to .9 DCY.
Reference values shown may vary 200/0 depending on operating conditions and other factors. RPM

ALL RIGHTS RESERVED
2.3L
OHC
TRUCK
RANGER
SENSORSI Signal
MAF@ 14 0 DCV .5 1.3-1.4 1.8-2.0 DCV

TP 47 1.0 DCV 1.0 1.2 1.5 DCV
EVP 27 .4 DCV .4 .7-.9 1.5 DCV
ECT 7 .8 DCV .8 .8 .8 DCV
ACT 25 1.5 DCV 1.8 ' 2.3 2.2 DCV
MAP 45 158 Hz 105-106 108-112 124-127 Hz
BP @ 45 158 Hz 158 158 . 158 Hz
10M 4 0 RPM 700-800 1700-2100 2700-3000 RPM
.-
PIP ,56 0 RPM 700-800 1700-2100 2700-3000 RPM
ACCS 10 0 DCV 0/VBAT0 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
NOS (A/T) 30 0 DCV 0 VBAT@ VBAT@ DCV
NGS/CES (MIT) 30 0 DCV 0 O/VBAT@ VBAT@ DCV
STI 48 5.0 DCV 5.0 '5.0 5.0 DCV
ACTUATORSI
OUTPUTS

SS 3/4 (A/T) 52 VBAT DCV VBAT yBAT .5 DCV
EVR 33 VBAT0 DCV 0 0 40 %
STO/MIL 17 .2 DCV VBAT \ ' . VBAT VBAT DCV
WAC 54 0 DCV 0/VBAT0 0 0 DCV
FP , 22 VBAT DCV .9 .9 .9 DCV
SPOUT 36 0 RPM 700-800 1700-2100' 2700-3000 RPM
DPI
.
32 11.0 DCV 0 0 0 DCV
OTHER
IGN TIMING TIMING 17-22 2430 27-30 DEG

- AIC on.
o- Monitor In DCV manual mode.
- Ranger MA vehicles only; NOS and NGS/CES values for MA vehicles Is 5.0 DCV.
HEGO In 'switching' mode ranges from .2' to .9 DCV.
vaiues are axle and tire dependent.

ALL RIGHTS RESERVED
2.9L
TRUCK
RANGER/BRONCO II
SENSORSI Signal
MAF @ 14 120 DCV .8 1.3-1.4 1.9-2.3 DCV

TP 47 1.0 DCV 1.0 1.1-1.2 1.3-1.4 DCV
EqT 7 .6 DCV .6 .6 .6 DCV
ACT 25 1.6 DCV 1.6 2.3 2.6 DCV
MAP 45 158 Hz 106-109 105-115 116-120 Hz
BP @ 45 158 Hz 158 158 158 Hz
10M 4 0 RPM 840-870 1300-1600 2400-2600 RPM
PIP 56 0 RPM 840-870 1300-1600 2400-2600 RPM
VSS+ 3 0 MPH 0 30 55 MPH
NDS (A/T) 30 0 DCV 0 VBAT@ VBAT@ DCV
NGS/CES (MIT) 30 0 DCV 0 O/VBAT@ VBAT@ DC
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORSI
OUTPUTS

SS 3/4 (A/T) 52 VBAT DCV VBAT VBAT VBAT DCV
SPOUT 36 0 RPM 840-870 1300-1600 2400-2600 RPM
OTHER
NOTES: 0 - Brake pedal depressed.

0- A/C on.
@- Clutch pedal depressed.
0- Monitor In DCV manual mode.
- MA Vehicles only; NOS and NGS/CES values for MA vehicles Is 5.0 DCV.

ALL RIGHTS RESERVED
EECIV Monitor Box: Intermi,ttent Fault -Diagnosis 18-49
3.0L
TRUCK
AEROSTAR -
SENSORSI Signal
INPUTS Pin :# KOEO Units HOT IDLE 30 MPH' 55 MPH Units
TP 47 .8 DCV .8 1.0-1.1 1.3-1.5 DCV

ECT 7 .6 DeV .6 .6
. .6 DCV
ACT 25 1.7 DCV 1.8 3.0 3.5 DCV
MAP 45 158 Hz 110-112 115-117 120-126 Hz
10M 4 0 RPM 750-800 1600-1800 2600-2800 RPM
PIP 56 0 RPM 750-800 1600-1800 2600-2800 RPM
BOO 2 0 DCV O/VBAT 0 . 0 0 DCV
FPM 8' 0 DCV VBAT VBAT' VBAT DCV
ACCS 10 0 DCV O/VBAT 0 '0 DCV
VSS+ - ,
3 0 MPH 0 30 55 -MPH
NOS (AfT) 30 0 DCV 0 VBAT VBAT DCV
NGSfCES (MIT) 30 0 DCV ' 0 O/VBAT@ VBAT DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORSI
OUTPUTS

.'
SS 3f4 (AfT) 52 VBAT DCV VBAT VBAT .7 DCV
STOfMIL 17 .6 DCV VBAT VBAT, VBAT DCV
DCV . DCV
CANP 31 VBAT VBAT 4.0-5.0 .2
WAC 54 0 DCV O/VBAT J 0 0 DCV
ISCBPA 21 VBAT DCV 10.6-11.8 9.6-10.0 9.0-9.8 DCV
FP 22 VBAT DeV .9 .9 .9- DCV
SPOUT 36 -0 RPM 750-800 -1600-1800 2600-2800 RPM
CCO (AfT) 53 VBAT DCV VBAT VBAT .7 DCV
OTHER , .
NOTES: Q) - .Brake pedal depressed.

- AIC on.
o - Monitor In DeV manual mode.
values are axle and 'tire dependent.
.,

ALL RIGHTS RESERVED
1850 EECIV Monitor Box:' Intermittent Fault Diagnosis
4.0L
APPENDIX: Diagnostic Reference Values EFI MA
TRUCK
RANGER/BRONCO II/AEROSTAR
SENSORSI Signal
INPUTS Pin :#: KOEO Units HOT IDLE 30 MPH 55 MPH Units
OCTADJ 44 0 DCV 0 0 0 DCV

MAF 14 0 DCV .6 1.3-1.4 1.7-2.0 DCV
TP 47 1.0 DCV 1.0 1.2-1.3 1.4-1.6 DCV
ECT 7 .6 DCV .6 .6 .6 DCV
ACT 25 2.2 DCV 2.6 2.7 2.9 DCV
BP 45 158 Hz 158 158 158 Hz
IDM 4 0 RPM 750-850 1500-1700 1800-2000 RPM
PIP 56 0 RPM 750-850 1500-1700 1800-2000 RPM
VSS+ 3 0 MPH 0 30 55 MPH
NDS 30 0 DCV 0 5.0 5.0 DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORSI
OUlPUTS

SS 3/4 (A/T) 52 VBAT DCV VBAl VBAl 0 DCV
STO/MIL 17 .6 DCV VBAT VBAT VBAl DCV
CANP 31 VBAT DCV VBAT 7.0-9.0 .2 DCV
ISC-BPA 21 VBAl DCV 8.0-12.0 7.3-8.4 5.5-6.8 DCV
SAW 36 0 RPM 750-850 1500-1700 1800-2000 RPM
CCO (A/T) 53 VBAl DCV VBAl VBAl 0 DCV
OTHER
IGN TIMING TIMING 10 10 10 DEG

- A/C on.
@ - Monitor in DCV manual mode.
HEGO In 'switching' mode ranges from .2 to .9 DeV.
Reference values shown may vary 20% depending on operating conditions and other

ALL RIGHTS RESERVED
4.9L
TRUCK
E and F - SERIES/BRONCO
SENSORS/ Signal
TP 47 1.0 DCV 1.0 1.2-1.3 1.5-1.6 DCV
EVP 27 .4 DCV .4 1.5-2.0 2.0-3.0 DCV
ECT 7 .6 DCV .6 .6 .6 DCV
ACT 25 1.2 qcv 1.2 1.6 1.6-2.0 DCV
MAP 45 158 Hz 106 107-112 120-135 Hz
IDM 4 0 APM 675-725 0 0 APM
OCS (E40D) 41 0 DCV 0 0 0 DCV
PIP 56 0 APM 675-725 0 0 APM
TOT (E40D) 23 1.7 DCV 1.2 1.2 1.2 DCV
KS 25 2.5 DCV 2.5 2.5 2.5 DCV
4x4l (E40D) 12 VeAT DCV veAT VBAT VBAT DCV
ACCS 10 0 DCV O/VBATe!) 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
ACD 43 0 DCV O/VBATe!) 0 0 MPH
NDS (AfT) 30 0 DCV 0 5.0 5.0 DCV
MlP (E40D) 30 4.5 DCV 4.5 2.1 2.1 DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORS/ .'
OUTPUTS
INJ Bank 1 58 VeAT@ DCV 6.4-6.8 7.5-9.5 11.0-12.5 mS
SS1 (E40D) 52 .3 DCV .4 ., VeAT VBAT DCV
EVA 33 VBAT@ DCV 0 0 0 %
EPC (E40D) 38 . 7.3 DCV 8.5 8.6 9.0 DCV
STO/Mll 17 .6 DCV VBAT veAT VBAT DCV
WAC 54 0 DCV o/veATe!) 0 0 DCV
SS2 (E40D) 19 VBAT DCV VBAT .4 .4 DCV
SPOUT 36 0 APM 675-725 0 0 APM
OCll (E40D) 32 veAT DCV. VBAT VBAT 0 DCV
AM1 51 VBAT DCV VBAT 0 0 DCV
AM2 11 VBAT DCV veAT VBAT veAT DCV
CCC (E40D) 53 veAT DCV VBAT .4 .4 DCV
CCS (E40D) 55 VBAT DCV VBAT VBAT .4 DCV
OTHER
NOTES: e!)- A/C on.

0 - Clutch pedal depressed.
@ - Monitor In DCV manual mode.
o- RPM values are transmission, axle and tire dependent.
Reference values shown may vary 20% depending on operating conditions and other factors.

ALL RIGHTS RESERVED
18-52 EEC-IV Monitor Box: I.ntermittent Fault Diagnosis
5.0L
APPENDIX: Diagnostic' Reference Values EFI
TRUCK
E AND F - SERIES/BRONCO
SENSORS/ Signal
INPUTS Pin 1/ KOEO Units HOT IDLE 30 MPH 55 MPH Units
TP 47 .9 DCV .9 1.0-1.1 1.2-1.3 DCV
EVP 27 .4 DCV .4 .4-.8 3.0-3.5 DCV
ECT 7 .6 DCV .6 .6 .6 DCV
ACT 25 1.2 DCV 1.2 1.4 1.2 DCV
MAP 45 158 Hz 104-105 107-112 122-124 Hz
10M 4 0 RPM 700-730 RPM
OCS (E40D) 41 0 DCV 0 0 0 DCV'
PIP 56 0 RPM 700-730 RPM
TOT 23 1.7 DCV 1.2 1.2 1.2 DCV
KS 23 2.5 DCV 2.5 2.5 2.5 DCV
4x4L (E40D) 12 VBAT DCV VBAT VBAT VBAT DCV
BOO (E40D) 2 0 DCV 0/VBAT0 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
NOS (A/T) 30 0 DCV 0 VBAT VBAT DCV
MLP (E40D) 30 4.5 DCV 4.5 2.1 2.1 DCV
NGS/CES (MIT) 30 0 DCV 0 O/VBAT@ VBAT DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORS/
OUTPUTS
SSl (E40D) 52 .3 DCV .4 VBAT VBAT DCV
EVR 33 VBAT0 DCV 0 0-50 . 75-90 %
EPC (E40D) 38 7.5 DCV 8.5 8.5 9.0 DCV
ISC-BPA 21 VBAT DCV 9.0 5.5-6.0 2.5-4.5 DCV
SPOUT 36 0 RPM 700-730 RPM
OCll (E40D) 32 VBAT DCV VBAT VBAT 0 DCV
AM1 51 VBAT DCV VBAT 0 0 DCV
AM2 11 VBAT DCV VBAT VBAT VBAT DCV
CCC (E40D) 53 VBAT DCV VBAT .4 .4 DCV
CCS (E40D) 55 VBAT DCV VBAT VBAT .4 DCV
OTHER
IGN TIMING TIMING 14 28-36 33-42 DEG
NOTES: 0 - Brake pedal depressed.

- A/C on.
0- Monitor In DCV manual mode.
- RPM values are transmission, axle and tire dependent.

ALL RIGHTS RESERVED
EEC-IV Monitor Box: Intermittent Fault Diagnosis .18-53
5.8L
TRUCK
E AND F - SERIES/BRONCO
SENSORSI Signal
TP 47 .9 DCV .9 1.1-1.2 1.3-1.4 DCV
EVP 27 .3 DCV .3 .4 1.2-16 DCV
ECT 7 .6 DCV .6 .6 .6 DCV
ACT 25 1.3 DCV 1.3 1.4 1.6-2.0 DCV
MAP 45 158 Hz 104-110 107-114 117-120 Hz
IDM 4 0 RPM 750-800 RPM
OCS (E40D) 41 0 DCV 0 0 0 RPM
PIP 56 0 RPM 750-800 DCV
TOT (E40D) 23 1.1 DCV 1.1 1.1 1.4 DCV
KS " 23 2.5 DCV 2.5 2.5 2.5 DCV
HEGO 29 0 DCV switching switching switching DCV~
4x4L (E40D) 12 VBAT DCV VBAT VBAT VBAT DCV
ACCS 10 0 DCV O/VBAT@ 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
NDS (A/T) 30 0 DCV 0 VBAT VBAT DCV
MLP (E40D) 30 4.5 DCV 4.5 2.1 2.1 DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORSI
OUTPUTS
INJ Bank 2 59 VBA T0 DCV 5.8-6.4 6.0-8.5 9.0-11.0 mS
SS1 (E40D) 52 .3 DCV .4 VBAT VBAT DCV
EVR 33 VBAT0 DCV 0 0-30 40 %
EPC (E40D) 38 7.2 DCV 8.5 8.9 9.0 DCV
CANP 31 VBAT DCV VBAT VBAT 0 DCV
ISC-BPA 21 VBAT DCV 8.3 5.0-7.0 3.0-4.0 DCV
OCIL (E40D) 32 VBAT DCV VBAT VBAT 0 DCV
AM2 11 VBAT DCV VBAT" VBAT VBAT DCV
CCC (E40D) 53 VBAT DCV VBAT 0 0 DCV
CCS (E40D) 55 VBAT DCV VBAT VBAT VBAT DCV
OTHER !

- A/C on.
o- Monitor In DCV manual mode.
@) - RPM values are transmission, axle and tire dependent.

ALL RIGHTS RESERVED
7.5L
TRUCK
E AND F - SERIES
SENSORSI Signal
INPUTS Pin #: KOEO Units HOT IDLE 30 MPH 55 MPH Units
TP 47 1.0 DCV 1.0 1.1-1.3 1.3-1.5 DCV

EVP 27 .4 DCV .4 .4 .4-4.0 DCV
ECT 7 .6 DCV .6 .6 .6 DCV
ACT 25 1.2 DCV 1.2 1.5 2.2 DCV
MAP 45 158 Hz 104 108-110 121-126 Hz
IDM 4 0 RPM 700-750 RPM
OCS (E40D) 41 0 DCV 0 0 0 DCV
PIP 56 0 RPM 700750 RPM
TOT (E40D) 23 1.5 DCV 1.5 1.5 1.4 DCV
KS 23 2.5 DCV 2.5 2.5 2.5 DCV
HEGO ' 29 0 DCV switching switching switching DCV
4x4l (E40D) 12 VBAT DCV VBAT VBAT VBAT DCV
VSS+ 3 0 MPH 0 30 55 MPH
NDS (AlT) 30 0 DCV 0 VBAT VBAT DCV
MlP (E40D) 30 4.4 DCV 4.4 2.1 2.1 DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORSI
OUTPUTS

SS1 (E40D) 52 .3 DCV .4 VBAT VBAT DCV
EVR 33 VBAT0 DCV 0 0 0-60 %
EPC (E40D) 38 7.3 DCV 8.8 9.0 9.0 DCV
CANP 31 VBAT DCV VBAT .2-12.0 .2 DCV
OCll (E40D) 32 VBAT DCV VBAT VBAT 0 DCV
CCC (E40D) 53 VBAT DCV V8AT .4 .4 DCV
CCS (E40D) 55 VBAT DCV VBAT VBAT .4 DeV
OTHER
NOTES: (i) - Brake pedal depressed.

- AIC on.
- RPM values are transmission, axle and tire dependent.
HEGO In 'switching' mode ranges from .2 to .9 DeV.

ALL RIGHTS RESERVED
7.3L
APPENDIX: Diagnostic Reference Values DIESEL
E40D
Truck
E AND F - SERIES
SENSORSI Signal
FIPl . 47 1.2 DCV 1.2 1.8 2.0-2.3 DCV
TOT 7 2.0 DCV 1.4 1.8 1.8 DCV
BP 45 157 Hz 157 157 157 Hz
RPMS 4 0 RPM 650-700 RPM
OCS 41 0 DCV 0 0 0 DCV
4x4l 12 VBAT DCV VBAT VBAT VBAT DCV
BOO 2 0 DCV 0/VBAT0. 0 0 DCV
VSS+ 3 0 MPH 0 30 55 MPH
MlP 30 4.5 DCV 4~5 2.1 2.1 DCV
STI 48 5.0 DCV 5.0 5.0 5.0 DCV
ACTUATORSI
OUTPUTS
SS1 52 .3 DCV .4 VBAT VBAT DCV
EPC 38 9.0 DCV 8.0 8.0 8.5 DCV
STO 17 VBAT DCV VBAT VBAT VBAT DCV
SS2 19 VBAT DCV VBAT .4 .4 DCV
OCIL/Mll 32 VBAT DCV VBAT VBAT 0 DCV
ecc 53 VBAT DCV VBAT .4 .4 DCV
CCS 55 VBAT DCV VBAT VBAT .4 DCV

- A/C on.
- RPM values are transmission, axle and tire depende~t.

ALL RIGHTS RESERVED
APPENDIX: EEC-IV Graphs and Charts
EEC-IV GRAPHS & CHARTS
ACT : 18-57 MLP 18-61

ECT 18-57 PFE 18-61
EVP 18-58 TOT 18-62
FIPL 18-58 TP 18-62
Fuel Pressure 18-59 VAF 18-63
MAF 18-59 VAT 18-63
MAP/BP 18-60
STATIC RESISTANCE VALUES
Device Acceptable Device Acceptable

Range (Ohms) Range (Ohms)
AM1 50 to 100 lAC 50 to 100
AM2 50 to 100 ISC-BPA 7 to 13
CANP 40 to 90 LUS 20 to 40
CCC 16 to 30 SBS 50 to 100
CCO 26 to 40 SCVAC 40 to 75
CCS 16 to 30 SCVNT 100 to 150
EDF 65 to 110 SS 3/4 26 to 40
EGRC 30 to 70 WAC 50 to 70
EGR SIO 65 to 110 WAC/IRCM 1K min.
EGRV 30 to 70
EPC 3 to 6.5
EVR 30 to 70
FP 40 to 90
FP/IRCM 65 to 110
HEDF/IRCM 50 to 100
Injectors Refer to Section 17

ALL RIGHTS RESERVED
ACT
APPENDIX: . EEC-IV Graphs' and Charts and
ECT
ACT Sensor Graph
TEMPERATURE ACT SENSOR DATA * Voltage values calculated

OF 0C for VREF=5.0v (These
248 0 120 0 values may vary 15% due
to sensor and VREF
variations).
TEMPERATURE VOLTAGE* RESISTANCE
OF C Volts K ohms
248 120 0.28 1.18
230 110 0.36 1.55
212 100 .47 2.07
194 90 .61 2.80
176 80 .80 3.84
158 70 1.04 5.37
140 60 1.35 7.60
68 0 20 0 122 50 1.72 10.97
104 40 2.16 16.15
86 30 2.62 24.27
320 0 0 L-_...l..-_---ll..---'""---~-........ 68 20 3.06 37.30
Ov 1v 2v 3v 4v 5v 50 10 3.52 58.75
1.1 k 5.4k 14k 37k 118k
Resistance Reading (ohms) A12843.A
ECT Sensor Graph
TEMPERATURE ECT SENSOR DATA * Voltage values calculated

OF 0C for VREF=5.0v (These
values may vary 15% due
248 0 120 0 to sensor and VREF
variations).
212 0 1000~
I-
1760 '800~
OF C Volts K ohms
I- 248 120 0.28 1.18
230 110 0.36 1.55
140 0
60 0
t- 212 100 .47 2.07
I- 194 90 .61 2.80
1040 400~ 176 80 :80 3.84
~ 158 70 1.04 5.37
68 0 200~
140 60 1.35 7.60
122 50 1.72 10.97
~ 104 40 12.16 16.15
32 0 L._.....L_ _..J-_~.....
00 1 I ---:--1__-=1,,- 86 30 12.62 24.27
Ov 1v 2v 3v 4v 5v 68 . 20 13.06 37.30
Voltage Reading (volts) 50 10 13.52 58.75
1.1k 5.4k 14k 37k 118k
Resistance Reading (ohms) A12842.A

ALL RIGHTS RESERVED
EVP
APPENDIX: EEC-IV Graphs and Charts and
FIPL
EVP Sensor Graph

%EGR EVP SENSOR DATA * Voltage values calculated
for VREF=5.0v (These
to sensor and VREF
variations).
%EGR VOLTAGE*
o 0.40
10 . 0.75
20 1.10
30 1.45
40 1.80
50 2.15
60 2.50
70 2.85
80 3.20
90 3.55
0% l..-l~--+---+---+---t------t 100 3.90
Ov, 1v 2v 3v 4v 5v
A12844-A
FIPL Throttle Angle

DEGREES FIPL SENSOR DATA * Voltage values calculated
to sensor and VREF
variations)
THROTTLE ANGLE VOLTAGE*

DEGREES VOLTS
0 0.50
10 0.97
20 1.44
30 1.90
40 2.37
50 2.84
0
0 ""'-....c;.-+---O+----+--;..-.-+----4 60 3.31
70 3.78
Ov 1v 3v 4v 5v 80 4.24
VOLTAGE READING (VOLTS)
A12833-A

ALL RIGHTS RESERVED
Fuel
APPENDIX: EEC-IV Graphs and Charts Pressure,
MAF

1990 PASSENGER CAR ENGINES
2.3L 3.0L 3.8L ALL
1.9L/2.5L HSC SHO SC OTHER
GFI EFI SEFI SEFI APPLICATIONS
ENGINE 13-17 PSI 45-60 PSI 28-33 PSI 3045 PSI 30-45 PSI
RUNNING 90-120 kPa 310-415 kPa 193-227 kPa 210280 kPa 210-310 kPa
KEY ON 13-17 PSI 50-60 PSI 30-45 PSI 35-40 PSI 35-40 PSI
ENGINE OFF 90-120 kPa 345-415 kPa 210-310 kPa 240-280 kPa 240-280 kPa
1990 Light Truck Engines

4.9L ALL
OTHER
EFI APPLICATIONS
RUNNING 310-415 kPa 210-310 kPa
I--------+---------t
KEY ON 50-60 PSI 35-45 PSI
ENGINE 345-415 kPa 240-310 kPa
OFF
MAF Sensor Graph
VOLTAGE
(V)
MAF SENSOR DATA * Engine at Normal Opera.ting
- Temperature.
3.0 --
..
-- ENGINE
CONDITION
VOLTAGE
VOLTS
2.0 -~
- IDLE
20 MPH
.8
1.0
~
40 MPH 1.7
~ 60 MPH 2.1
1.0 .. -
............
'"
'"
'" I I I j
IDLE 20 mph 40 mph 60 mph

A12846-B

ALL RIGHTS RESERVED
APPENDIX: EEC-IV Graphs and Charts MAP/BP
BP Sensor Graph
MAP Sensor Graphs: Output Frequency at Key On/Engine Off
MAP/BP SENSOR DATA:
OUTPUT FREQUENCY AT KOEO
MAP FREQUENCY (Hz) Frequency may vary plus or
165 minus 6 Hz of these values
164
163 due to sensor variations.
162
161
160
159 ~-----~......-
158
BAROMETRIC PRESSURE FREQUENCY
157
156
155 in. (Hg) kPa Hz *
154
153
152
17.1 58 122.4
151
150
18.3 62 125.5
149 19.5 66 128.7
""''!''''I'''''I''''I''''1''''I'''"I''''I'''nr-I''''1"''P'''1''''I''''I''"r''''Jl'''l''''l''''1I''''1''''I''''I'''',.....r
28.8 29.0 29.2 29.4 29.6 29.8 30.0 30.2 30.4 30.6 30.8 31.0 31.2 20.7 70 131.9
21.8 74 135.1
BAROMETRIC PRESSURE (In. Hg) 23.0 78 138.3
95.0 96.0 970 980 99.0 100.0 101.0 1020103.0 104.0 105.0 '106.0 1070
24.2 82 141.8
25.4 86 145.4
BAROMETRIC PRESSURE (kPa) 26.6 90 148.9
27.7 94 152.5
28.9 98 156.1
A12835-B
30.1 102 159.6
31.0 105 162.4
Manifold Vaccum
In * MAP output frequency versus
(Hg) kPA manifold vacuum data is
based on 30.0
in. (Hg) Barometric Pressure.
o 0
3 10.2 MANIFOLD VACUUM FREQUENCY
6 20.3 In. (Hg) kPa Hz *
9 30.5
0 0 159
12 40.6 3 10.2 150
15 50.8 6 20.3 141
9 30.5 133
18 61.0 12 40.6 125
21 71.1 15 50.8 117
18 61.0 109
24 81.3 21 71.1 102
27 91.5 24 81.3 95
27 91.5 88
30 101.6 ...-t--+-t-+--+-t-+--+--+~ 30 101.6 80
60 80 100 120 140 160
MAPOUTPUTFREOUENCV(Hz)
A12836-A

ALL RIGHTS RESERVED
MLP
APPENDIX: EEC-IV 'Graphs and Charts and
PFE
MLP Sensor Graph
TRANSMISSIoN
POSITION MLP SENSOR DATA * Voltage values calculated
to sensor and VREF
P I variations) J
R I Transmission Voltage* Resistance

N I Shift Position Volts Ohms
0
I p
R
4.41
3.60
4.16K
1.44K
'2
I N
0
2.83
2.09
733
401
I I , I I I 2 1.37 211-
Ov 1v 2v 3v 4v 5v 1 .68 81
VOLTAGE READING (VOLTS) *
95 430 1.25K 3.66K
RESISTANCE READING (OHMS)
A12837A
PFE Sensor Graph
PFE SENSOR DATA * Voltage values calculated

PRESSURE for VREF=5.0v ,(These
VACUUM values may vary :t- 15% due
kPa
to sensor and VREF
variations)
PRESSURE/VACUUM
10
5 PSI In. Hg kPa VOLTAGE *
o 1.82 12.5 4.75
1.36 9.42 4.38
5 0.91 6.25 4.0
10 0.46 3.17 3.63
o 0 0 3.25
15 5 -17 1.22
20 7.4 25 0.25
25........~--+-- ....--+--""'--+-""'--+----t CAUTION: To avoid possible sensor damage
do not exceed pressure/vacuum
Ov 1v 2v 3V' 4v 5v range shown when testing.
Voltage Reading (volta)

A12845-A

ALL RIGHTS RESERVED
TOT
TP
TOT Sensor Graph

TEMPERATURE TOT SENSOR DATA * Voltage values calculated
of C for VREF=5.0v (These
248 120 to sensor and VREF
variations)
212
176 0 80
OF C Volts K ohms
248 120 0.28 1.18
140 60 230 110 0.36 1.55
212 100 .47 2.07
104 40 194 90 .61 2.80
176 80 .80 3.84
158 70 1.04 5.37
68 20
140 60 1.35 7.60
122 50 1.72 10.97
32 0 104 40 2.16 16.15
Ov 1v 2v 3v 4v 5v 86 30 2.62 24.27
VOLTAGE READING (VOLTS) 68 20 3.06 37.30
50 10 3.52 58.75
1.1 k 5.4k 14k 37k 118k
RESISTANCE READING (OHMS) A12838-A
Throttle Angle
DEGREES TP SENSOR DATA * Voltage values calculated
to sensor and VREF
variations)
THROTTLE ANGLE VOLTAGE*

DEGREES VOLTS
o 0.50
10 0.97
20 1.44
30 1.90
40 2.37
50 2.84
60 3.31
70 3.78
Ov 1v 2v 3v 4v 5v 80 4.24
VOLTAGE READING (VOLTS)

A12839-A

ALL RIGHTS RESERVED
VAF
VAT
VAF Sensor Graph

VANE
POSITION VAF SENSOR DATA * Voltage values calculated
values may vary 15 % due
to sensor and VREF
OPEN variations)
VANE POSITION VOLTAGE

VOLTS
Vane Closed .25v
Vane Full Open 4.50v
Ov 1v 2v 3v 4v 5v
VOLTAGE READING (VOlTS)

A1284G-A
VAT Sensor Graph

TEMPERATURE
VAT SENSOR DATA * Voltage values calculated
OF 0c for VREF=5.0v (These
248 0 120~ values may vary 15 % due
to sensor and VREF
variations)

of C Volts K ohms
248 120 0.38 0.11
230 110 0.46 0.14
1400 60 0 212 100 0.56 0.19
194 90 0.76 0.25
176 80 0.95 0.33
1040 40 0 158 70 1.19 0.44
140 60 1.49 20.60
122 50 1.84 0.83
104 40 2.23 1.18
32 0 O""'--_~ _ _"""_ _-+-_ _ """_---1 86
68
30
20
2.65
3.07
1.70
2.50
Ov 1v 2v 3v 4v 5v 50 10 3.46 3.77
Voltage Reading (volta)
0.1 k 0.35k 0.97k 2.34k 8.11 k
Resistance Reading (ohms) A12841-A

ALL RIGHTS RESERVED
SECTION 19
Diesel Diagnosis~
6.6L and 7.8L Ford Diesel Engines
Contents
Preliminary Check~ut : 19-1
Test ~quipment 19-3
.Engine Performance Specifications 19-6
Engine Lubrication System 19-7
High and Low Idle Speed Check and Adjustment 19-9
Dynamic Timing : ~ 19-11
Static Timing '......................... 19-14
Fuel System Description : 19-17
Symptom Analysis 19-18
Pinpoint Tests 19-20
Engine Performance Diagnosis Procedure 19-44
Injector Nozzle Testing : : " ~ 19-57
Checking Compression ' " 19-60

ALL RIGHTS RESERVED
Diesel Diagnosis - 6.6L and 7.8l Ford Diesel Engines 191
_I Preliminary Checkout
This Section covers Adjustments, Diagnosis, and Test procedures for the 6.6L and 7.8L Ford
Diesel engines. The areas included are the low-pressure fuel system, high-pressure (fuel
injection) fuel system, air induction system, turbocharger, lubrication and' cooling systems.
Before Starting
Efficient diagnosis must take place in an organized manner. with a plan or procedure which
starts with the obvious and goes on to the more difficult. E1i!llinate all the obvious and easy-
to-do items first. Do not start by jumping to conclusions. The job worked on last week might
have been caused by an entirely different problem than the one today.
Get All The Information Available

Check out all sources of information. Talk to the operator. Sometimes asking a question will
cause the operator to remember something that is useful.
The following list is a set of basic questions. Get the answers to these in order to learn what
the true complaint is, and what the basic problem is.
Operating Conditions:
1. Did the problem occur suddenly or over a long period of time?
2. Were there any abnormal noises before the failure?
3. Was the engine under heavy or light load? Decelerating or accelerating?

4. Did the water temperature or oil pressure vary?
5. Were weather conditions a factor?
6. What type of road grade was the vehicle on when the trouble was first noticed?
7. How was the trouble first noticed (felt, heard, etc.)?

8. What was the amount of oil consumption? Fuel? Coolant? Had there been a recent
change?
9. . What was the exhaust smoke like? Light or dense? Color? I
1O. Does the engine have good throttle response?
11. Is deceleration normal?

12. Does the engine shut off properly?
13. Does the engine start correctly when cold?
14. Does the engine ever miss?
15. What kind of fuel is being us~d? Grade and source?
16. Does the engine surge at idle or wide-open throttle?

17. Is the engine subjected to periods of extended idling?
18. Has the vehicle or equipment been in an accident or collision?

ALL RIGHTS RESERVED
19-2 Diesel Diagnosis - 6.6L and 7.8L Ford Diesel Engines
__p_r_e_li_m_i_D_a_ry_C_h_e_c_k_o_u_t 1.
Maintenance History:
1. Has the engine been serviced recently? What was done?
2. Has this complaint occurred before? If so, what was done then?
3. When was the last tune-up?
4. When were the oil and fuel filters last changed?
5. Who normally performs the maintenance and adjustments?
6. Is the maintenance schedule followed closely?
7. How is fuel obtained and stored?
8. What type service designation (SG/CE), and what grade oil is used?
9. How many miles or hours has the engine operated since the last service?
Observed Information:
1. Is the engine clean or dirty?
2. Are the belts in good condition? Loose?
3. Is there evidence of external oil, coolant or fuel leaks?
4. Does the engine appear to have overheated?
5. Are there any make-shift repairs on the engine (loose parts, wired-on parts, etc.)?
6. How does the engine sound at idle?
7. Are any pulleys wobbling?
8. Do any parts appear to have been altered or serviced recently?
9. Are there any aftermarket or unapproved parts on the engine?
10. Have any of the lines been altered or re-routed?
11. Are oil level, coolant level and fuel level satisfactory? (If the problem concerns bearings,
notice the condition of the oiL)
12. During disassembly, does the engine have unusual odors, carbon accumulations, dirt 9r
other conditions under the rocker cover?

ALL RIGHTS RESERVED
Diesel Diagnosis - 6.6L and 7.8L Ford Diesel Engines 193
Test Equipment
The following test equipment (Figures 1 through 4) is required for adjusting idle speed and
timing.
TOOL T87T-6379.A
a-RING
A12723A
A9278-C
Figure 1 Photoelectric Tachometer, Figure 3 Timing Lock Pin - Damper

Rotunda 055-00108 T87T-6379-A
Checking Engine
TOOL T87T9000-B
OFFSET
ANGLE
CONTROL
BATTERY
CONNECT
CLAMPS
MAGNETIC
\ \o4-_ _ PICK-UP
PROBE
078-00123
A950700C
A8277-8
Figure 2 Dynamic Timing Meter, Rotunda Figure 4 Timing Lock Pin - Injector Pump
078-00200 T87T-9000-B

ALL RIGHTS RESERVED
Test Equipment
The following test equipment (Figure 5) is required for performing the Engine Performance
Diagnostic procedure.
Figure 5 Rotunda 014-00762 Pressure Test

Kit Used with Rotunda Adapter Kit
014-00733, 014-00742
The following test equipment (Figure 6) is used to test engine compression.
A9281-8
Figure 6 Rotunda Compression Tester

01400701 Requires Adapter
01400731

ALL RIGHTS RESERVED
Test Equipment
The following test eq':Jipment (Figure 7) is required for injection nozzle testing and cleaning.
A8557-8
Figure 7 Rotunda Injector Nozzle Tester

014-00300 (Special Service Tool
D83T-9000-F)

ALL RIGHTS RESERVED
196 Diesel Diagnosis - 6.6L and 7.8L Ford Diesel Engines
1990 Ford Diesel

Engine Performance Specifications
6.6l Turbo 7.8l Turbo
Engine Horsepower 165 170 185 185 210 215 215 240 270
Engine Certification (States) 50 50 50 50 50 50 50 50 50
(BHP @ 2400 rpm) 185 185 210 215 240 270
Engine Rating (BHP @ 2600 rpm)
(BHP @ 2000 rpm) 165 170 215
Firing Order 153-6-2-4
Injection Pump Robert

A-2000 P-3000 A-2000 P-3000 P-3000 P-3000 P-3000 P3000
Make and Model Bosch
Turbocharger Make Garret

T04E T45
and Model Airesearch
Injection Nozzle Make Robert Bosch
Injection Nozzle 3680- 3100-

PSI 3100-3220 3680-3800
Opening Pressure (New) 3800 3220
Minimum Allowable
PSI 2870 3390 2870 3390
Opening Pressure (Used-Service Check)
Injection Pump Static Timing - BTDC 14 10 14 14 10 11 10 11 12
Injection Pump Dynamic Timing - (No Load) @

1000 rpm CD CD CD CD CD CD CD CD CD
Low Idle Speed - Man. and Auto. Transmission 700-750
2960- 2740- 2740- 2740- 2740- 2740- 2760- 2780-

High Idle Speed 2930-3010
3040 2820 2820 2820 2820 2820 2840 2840
14 1 17 1 16 1 14 1 16 1 22.6
18 1 20 1 18 1
psi psi psi psi psi 1 psi
psi psi psi
(97 7 (117 (110 (97 7 (110 (152
Intake Manifold (Turbo Boost) Pressure - Full (124 7 (138 7 (124 7
kPa) 7 kPa) 7 kPa) kPa) 7 kPa) 7 kPa)
Load @ rated rpm kPa) kPa) kPa)
@ @ @ @ @ @
@ 2600 @ 2600 @ 2400
2400 2400 2000 2400 2400 2400
rpm rpm rpm
rpm rpm rpm rpm rpm rpm
3 in. H20 (.7 kPa) @

Crankcase Pressure (max. allowable), no load 3 in. H2 0 (.7 kPa) @ 2400 rpm
2600 rpm
@ 2400 rpm
Air Filter Restriction @ rated rpm, no load @ 2600 rpm
(Max) 10 in H20 (2.5 kPa)
(Min) 15 psi (103.43 kPa)

Fuel Pressure (filter inlet)
(Max) 30 psi (206.85 kPa)
(Min) 15 psi (103.43 kPa)

Fuel Pressure (filter outlet)
(Max) 28 psi (193.06 kPa)
Pressure Drop Across Fuel Filter (Max) 7 psi (48.27 kPa)
Lift Pump Suction @ rated rpm, no load (Max) 10 in H20 (2.5 kPa)
Fuel Return Line Pressure - no load (Max) 6 psi (41.37 kPa)
Low Idle: (Min) 15 psi (103 kPa)

Lubricating Oil Pressure at Operating Temperature
High Idle: 6595 psi (488-655 kPa)
CD Not available at time of publication.

ALL RIGHTS RESERVED
Diesel Diagnosis - 6.6l and 7.8l Ford Diesel Engines 19-7
Engine Lubrication System

1
ROCKER
ARM
SHAFT
~ UNFILTERED OIL
OIL FILTER --. FILTERED OIL
(SECONDARY)
Fig!Jre 8 6.6L and 7.8L Ford Diesel Lubrication System

ALL RIGHTS RESERVED
198 Diesel Diagnosis - 6.6l and 7.8l Ford Diesel Engines
Engine Lubrication System
OIL GALLERY
I
I
I I I GEAR
I
I
I
I
I
I
I '
I::=::=::::
TIMING
CEAR
L L==-=-__-,-,
I
I
L_
ROO-GRANK
BEARINGS
I I
--------, I
"---_-~I I
I I
I I
I I
I I
I I
I I
OIL COOLER
I IL... ,
I ------ I I
IL-----,'
----...., I'
I
I I,I I
OIL PUMP
I I II I
I III I ,.-----1
I 1111 I r------------- J
I II I I I I
PRESSURE LINE
- - - - - SPLASH OR EXHAUST
OIL PAN
OIL PICKUP
A9928-B
Figure 9 6.6L and 7.8L Ford Diesel Engines

ALL RIGHTS RESERVED
Diesel Diagnosis - 6.6L and 7.8L Ford Diesel Engines 19-9
High and Low Idle Speed Check and Adjustment
1. Clean crankshaft vibration damper and apply reflective tape at point shown in Figure 10.
NOTE: If dynamic timing meter is being used to check engine -rpm, application of
reflective tape on vibration damper is not necessary. Refer to Dynamic Timing
for instructions on meter hookup.
APPLY REFLECTIVE
TAPE HERE A9929-C
Figure 10 Reflective Tape Application
2. Place transmission in NEUTRAL or PARK and set the parking brake.,
3. Bring engine to normal operating temperature: The 'engine must have been running at
least 10 minutes prior to any adjustment.
4. Low idle speed is measured with manual transmission in' NEUTRAL and automatic
transmission in PARK.
5. Ensure that the throttle lever is against the low idle stop. If .oot, adjust linkage. Refer. to
Shop Manual, Section '25-60.

ALL RIGHTS RESERVED
High and Low Idle Speed Check and Adjustment
6. Check idle speed using Rotunda Photoelectric Tachometer 055-00108 or equivalent. Low
idle speed is specified on the Vehicle Emission Control Information (VECI) decal. Turn
adjusting screw (Figure 11) counterclockwise to increase speed, clockwise to decrease
speed.
A92S5-C
Figure 11 Adjusting Screw
7. Place transmission in NEUTRAL or PARK. Rev engine momentarily. Place transmission in

specified gear (automatic transmission only) and recheck curb idle rpm. Adjust if
necessary.
8. High idle speed is measured with manual transmission in NEUTRAL and automatic
transmission in PARK or NEUTRAL.
9. Ensure that the throttle lever is against the high idle stop when the accelerator pedal is
fully depressed. If not, adjust the linkage. Refer to Shop Manual, Section 25-60.
10. Check high idle speed using Rotunda Photoelectric Tachometer 055-00108 or equivalent.
11. If high idle speed is not correct, determine the problem. If the high idle is too low, go to
the Engine Performance Diagnosis procedure. If the engine is overspeeding, the fuel
injection pump should be sent to an authorized service center for inspection and
diagnosis.
i CAUTION!
High idle speed is not to be adjusted. Breaking the seal on the high idle stop screw
will void the warranty.

ALL RIGHTS RESERVED
I Dynamic Timing
Engine timing is verified by using the timing bracket. (Figure 1'2) located beside the crankshaft
damper. The timing bracket contains holes for checking dynamic timing and static timing.
Positioning of the bracket is very important because if it is loosened. or moved, timing will not
be correct. The bracket is accurately positioned and chisel marked to the front cover during
engine production. These chisel marks must always be aligned. Never loosen or remove the
timing bracket.
) .~
DAMPER ALIGNING
PIN
T87T-6379A A12676-A
Figure 12 Timing Pin and Probe Bracket
Dynamic timing is used as a quick check of timing. Do not, under any circumstances, change
or set engine timing based only on dynamic timing readings. Timing is to be verified and reset
only with the Timing Lock Pins T87T-9000-8 and T87T-6379-A or equivalent using the static
timing method. ..

ALL RIGHTS RESERVED
Dynamic Timing
1. With engine stopped, install Rotunda Dynamic Timing Meter 078-00200 or equivalent. Place
the magnetic pickup into the timing bracket pointer hole (Figure 13). Attach the connector
from the pickup to the. meter lead.
NOTE: To prevent incorrect readings, make sure that the vibration damper grooves
are clean and free of debris and rust. The pickup groove in the damper must
not be plugged, or readings will be inaccurate.
Figure 13 Inserting Magnetic Pickup Into

Timing Bracket
2. Attach the pressure transducer to the No. 1 injector line (Figure 14) at the injector. Be
sure the injector line is clean and free of paint where transducer is attached. Tighten the
thumbscrew on the transducer finger-tight when attaching to the injector line.
INJECTION
NOZZLE
NUT
A8217-8
Figure 14 Pressure Transducer Attachment

NOTE: Cracks or other damage to the pressure transducer can cause incorrect
timing readings. Follow these procedures carefully when working with
pressure transducers.
Do not over-tighten the transducer; snug fit is all that is needed. Do not use hand tools
to tighten.
Attach the transducer at the same location along the high-pressure line each time a
check is made. The timing reading will change if the transducer is placed at a different
location along the injector line.

ALL RIGHTS RESERVED
Dynamic Timing
The transducer should be dry; wet conditions will give erratic readings. If erratic readings
are observed, remove transducer, wipe line and transducer with a clean, dry cloth. Spray
the transducer and line with "a water-displacing material, and clamp on the injector line.
3. Connect the timing meter to the battery and adjust the offset angle on the meter to zero
degree~.
i CAUTION!
Be sure that all wire leads are located away from the front accessory drive belts and
cooling fan.
. 4. With the transmission in NEUTRAL or PARK and the parking brake set, start the engine.
Set the engine speed at 1000 rpm with no load, and observe the timing meter.
5. Check the Engine Performance Specifications for the correct timing specification for the
engine being serviced and compare with observed reading.
6. Turn the engine' off and remove the dynamic timing components.
7. If timing is off more than 2 degrees and there are indications of incorrect timing, such as
poor performance 'or smoke, check the static timing using the lock pins. If the engine is
performing normally and there is no evidence of excessive smoke or poor performance,
check all meter connections and, if necessary, have meter calibration verified.

ALL RIGHTS RESERVED
Static Timing
Pump On Engine (Check Timing)

1. Rotate engine clockwise. Set engine at correct static timing angle with No. 1 piston on
the compression stroke. Fit Timing Lock Pin T87T-6379-A through the timing bracket into
the correct crankshaft damper groove (Figure 15).
7.8L 6.6L NAAO 6.6L NAAO

185HP
210HP 170HP
215HP
240HP
270HP
(ALTERNATE
LOCATIONS)
II \I1~- STATICTIMING
PIN HOLE
A12677B
Figure 15 Fitting Timing Pin Into Crankshaft Figure 16 Tach Sensor or Plug Location
Damper .
NOTE: The proper timing angle on the compression stroke of No. 1 cylinder is indicated
by removing No. 1 Injector and feeling for compression while turning the engine
In the direction of rotation. When compression is felt, continue turning the
engine until the alignment pin drops Into the appropriate groove in the
crankshaft damper cover. This indicates that the engine crankshaft is at the
correct static timing angle with No. 1 piston on the compression stroke. Always
approach the lock pin groove while turning the engine clockwise to ensure that
gear backlash will not affect timing.
NOTE: When unable to access front damper mounting bolt to rotate engine, remove
plug or tach sensor at top of flywheel housing to rotate flywheel ring gear with
large screwdriver (Figure 16).
i CAUTION!
Do not, under any circumstances, loosen or remove the timing bracket.

ALL RIGHTS RESERVED
Static Timing
2. Remove the plug from the injector pump adapter plate timing pin location and install
timing lock pin into the adapter plate (Figure 17).
3. It is important that the lock pin seats fully in the slot in the injection pump hub (to within
3mm (1/8-inch) of the shoulder of the lock pin) to shoulder of eccentric pin lock screw.
This verifies proper engine timing. If the lock pin is not fully seated the timing will be
incorrect.
i CAUTION I
Do not turn crankshaft with timing lock pins in place.
Figure 17 Lock Pin in Adapter Plate Figure 18 Injection Pump Gear Hub Adjusting
Installation Screws
NOTE: To properly adjust timing, be sure the damper timing pin is installed in the
proper location with the No. 1 piston on the compression stroke.
4. To adjust timing, loosen the four adjusting screws on the injection pump gear hub (Figure
18). Rotate the pump shaft until the pump timing lock pin can be pushed into position
and fully seated. .
5. Turn gear counterclockwise by hand to remove backlash (it will move slightly). Tighten the
four adjusting screws to 7 N-m (5 Ib-ft). Remove the lock pins and tighten the adjusting
screws to 22-34 N-m (16-25 Ib-ft). Replace plug and sealing washer in adapter plate
timing pin hole. Tighten to 9-12 N- m (7-9 Ib-ft).
6. Rotate engine counterclockwise 90 degrees and then clockwise to the point where timing
lock pin can be inserted in crankshaft damper. Insert timing lock pins into crankshaft
damper and into fuel injection pump hub. If pin seats in injection pump gear hub, timing is
correct. If ~t does not seat, repeat timing procedure.
Injection Pump Removed From Engine - Timing Bracket Removed or loosened
1. Align timing bra'cket chisel mark with chisel mark on engine front cover. Tighten the timing
bracket screw to 9-12 N-m (7-9 Ib-ft).
NOTE: If a new timing bracket is being installed, it is necessary to accurately position
the timing bracket with the damper timing groove. This requires a special
procedure found in Shop Manual, Section 22-12.

ALL RIGHTS RESERVED
Static Timing
2. Lock the fuel injection pump at port closure by inserting the lock pin into the fuel injection
pump adapter housing so that it locks into the slot in the injection pump hub.
3. Set the engine, with No. 1 cylinder on the compression stroke, at static timing angle using
the timing bracket and lock pin. Rotate the engine at least 20 degrees counterclockwise,
then clockwise until the lock pin in the timing bracket engages the correct groove in the
damper cover.
4. Loosen the four adjusting screws on injection pump gear hub.
5. Install the injection pump on the engine and align the adapter bolt holes to holes on
engine. Install pump bolts and tighten to 27-34 Nom (20-25 Ib-ft).
6. Rotate the pump gear counterclockwise to remove the pump gear backlash. Tighten the
four adjusting screws on the hub to 7 Nom (5 Ib-ft). Remove the timing lock pin from the
pump. Tighten the four adjusting screws to 22-34 Nom (16-25 Ib-ft). Install the lock pin
.hole plug to 9-12 Nom (7-9 Ib-ft).
7. Install engine components and check dynamic timing as outlined.
Injection Pump Off Engine - Timing Bracket Undisturbed
Perform Steps 2 through 7 of Static Timing: Injection Pump Off Engine - Timing Bracket
Removed or Loosened.

ALL RIGHTS RESERVED
Diesel Diagnosis - 6.6l and 7.8l Ford Diesel Engines 1917
-I Fuel System Description
Figure 19 shows the two sides of the fuel system. In the low-pressure side, fuel pressure
does not normally rise above 206 kPa (30 psi). In the high-pressure side, fuel pressure can be
over 68,950 kPa (10,000 psi).
In the low-pressure side, fuel is supplied to the injection pump by the lift pump. Fuel flows
from the fuel tank to the fuel box, to the lift pump, through the dual filters to the injection
pump.
In the high-pressure side, the injection pump plungers raise the pressure to over 68,950 kPa
(10,000 psi) and distributes fuel to the injector nozzles by way of the high-pressure fuel lines.
Approximately 40% of the fuel reaching the fuel injection pump and injectors is used for
combustion. The remaining fuel cools and lubricates the fuel injection pump and injectors and
returns to the fuel tank through a fuel return line.
, FUEL INJECTORS
FUEL INJECTION
FUEL SHUTOFF INJECTION PUMP ,'A'TYPE
SOLENOID PUMP PUMP
LOW PRESSURE SIDE HIGH-PRESSURE SIDE A9303-C
Figure 19 Typical 6.6L, 7.8L Ford Diesel Engine Fuel System

ALL RIGHTS RESERVED
19-18 Diesel Diagnosis - 6.6L and 7.8l Ford Diesel Engines
__s_y_m_p_t_o_m_A_D_a_l_ys_i_S I-
Consult the Symptom Analysis Pinpoint Diagnosis procedures first. These will direct you to a
service to be performed or they will direct you to the Engine Performance Diagnosis
procedure.
If the problem is low power and/or increased fuel consumption, go directly to the Engine
Performance Diagnosis procedure.
Evaluating "Normal" Diesel Engine Exhaust Smoke
The following is a description of what is "normal" and expected exhaust smoke for a vehicle
with a diesel engine. Diesel exhaust smoke can vary in color and consistency. The following
chart should help in determining what causes certain types and colors of exhaust smoke and
what should be done. Normal diesel exhaust smoke can be classified into two categories
according to the color of the smoke.
The first category is blue-white smoke. Blue-white smoke may be observed at all ambient
temperatures but should not occur after the vehicle is warmed and being driven. Blue-white
smoke may occur after engine warm-up during extended idling due to the combustion
chambers cooling down.
NOTE: Chassis fuel system air leaks also may cause continuous heavy blue-white
smoke. Service fuel system as required.
The second category of diesel exhaust smoke is black smoke. Black smoke is caused by an
overrich mixture, and normally occurs whenever the engine is working hard. The engine works
hard when it is going up a steep grade, carrying a heavy load, or during heavy acceleration.
More black smoke will be observed when operating the vehicle at higher altitudes because the
air is thinner. If black smoke is observed while the engine is idling (at low altitude) or under
normal driving conditions, the problem should be diagnosed as soon as possible.
There is a third category of diesel exhaust smoke which is not normal; blue smoke. Blue
smoke occurs when oil is entering the combustion chamber and is burning along with the fuel.
Smoke of this color usually indicates a definite problem which should be corrected as soon as
possible.

ALL RIGHTS RESERVED
Symptom Analysis
Hard Starting/No Start Pinpoint Test A
Engine Surges Pinpoint Test B
Engine Misses Pinpoint Test C
Excessive Black Smoke Pinpoint Test D
Fog-Like Exhaust (White or Blue)

Pinpoint Test E
in Full-Load Range
Engine Cannot Reach Governed rpm Pinpoint Test F
Engine Knocks Pinpoint Test G
Turbocharger Noisy Pinpoint Test H
Cyclic Sound From Turbocharger Pinpoint Test J
Oil Leak From Turbocharger Compressor Pinpoint Test K

or Turbine Seal
Low Oil Pressure with Proper Oil Level Pinpoint Test L
Excessive Oil Consumption Pinpoint Test M
Fuel Dilution in Lubricating Oil" Pinpoint Test M
Excessive Coolant Temperature- Pinpoint Test P

Temperature Above 105C (220F)
Fuel Injection Pump Overheating Pinpoint Test Q
Low Power Go to Engin~ .

Performance Diagnosis
Procedure.
Increased Fuel Consumption Go to Engine

Performance' Diagnosis
Procedure.

ALL RIGHTS RESERVED
Pinpoint
IHard Starting/No Start Test
A-
AO I CHECK STARTING PROCEDURE
Check and follow correct starting procedure as @) ~ RETURN vehicle to

customer.
outlined in Owner's Manual.
fh ~ GO to IA11.
A1 I CHECK CRANKING SPEED
Check engine cranking rpm. @) ~ GO to IA21.

Cranking speed should be a minimum of 110 rpm.
fh ~ SERVICE cranking
system. REFER to
Shop Manual, Group
28.
A2 I CHECK FUEL FLOW
Check for fuel in fuel tank. @) ~ GO to IA41.

Loosen one injection line nut slightly while
cranking engine. Fuel should discharge.
fh ~ GO to IA31.
I WARNING I ..
BE EXTREMELY CAREFUL TO PREVENT BEING

STRUCK BY DIESEL FUEL UNDER PRESSURE.
DIESEL FUEL AT INJECTION PRESSURE CAN
EASILY PIERCE THE SKIN, POSSIBLY CAUSING
SEVERE SKIN POISONING. IF STRUCK BY
DIESEL FUEL, SEEK MEDICAL HELP
IMMEDIATELY.

ALL RIGHTS RESERVED
IHard Starting/No Start Pinpoint

Test
A
A3 I CHECK FUEL SHUTOFF SOLENOID
Check fuel shutoff solenoid link~ge for binding. @) ~ GO to IA41.

Check fuel solenoid shutoff electrical terminals for GO to Fuel Shut-Off
dirt or corrosion and loose or broken electrical Electrical System
connections. Diagnosis, Section 33-
48.
With ignition. in RUN position, measure voltage at
fuel shutoff solenoid. Voltage should be a
minimum of 9 volts.
~ ~ SERVICE or REPLACE
linkage or fuel shutoff
solenoid. REFER to
Shop Manual, Section
25-06. REPEAT Step
IA21.
A4 I CHECK STARTING AID
Check that starting aid is operating properly. Refer @) ~ GO to Engine

to Shop Manual, Section 28-12.
procedure.
~ ~ SERVICE starting aid.

REFER to Shop
Manual, Section 28-12.
REPEAT Ste~ IA41 .
NOTE: REVIEW
proper cold-starting
procedure with
customer, if
necessary.

ALL RIGHTS RESERVED
Pinpoint
IEngine Surges Test
B
80 I CHECK FUEL TANK
Check to see if fuel tank is empty or if tank vent

is blocked.
~ GO to Engine
procedure.
~ ~ FILL fuel tank. BLEED

air from fuel system.
CHECK tank vent.
REFER to Shop
Manual, Sections 25-06
and 25-50.

ALL RIGHTS RESERVED
IEngine Misses Pinpoint

Test
c
TEST STEP' RESULT ~ ACTION TO TAKE
CO I ISOLATE MISS
Loosen each injector nozzle line nut (one at a Miss not ~ GO to Engine
time) while engine is running. Refer to On-Vehicle isolated to Performance Diagnosis
Injector Nozzle T~sting. specific cylinder .procedure.
I WARNING I Miss isolated to

specific cylinder
~ GO to~.
BE EXTREMELY CAREFUL TO PREVENT BEING
STRUCK BY DIESEL FUEL UNDER PRESSURE.
EASILY PIERCE THE SKIN, POSSIBLY CAUSING
DIESEL FUEL, SEEK MEDICAL HELP
IMMEDIATELY.
C1 I CHECK NOZZLE FUEL DELIVERY
Check injector nozzle fuel line(s) for damage or

restrictions.
@) ~ GO to IC21.
Perform injector nozzle test as outlined under On

Bench Injection Nozzle Testing. r$J ~ .CLEAN or REPLACE
restricted or damaged
line(s). REFER to Shop
REPLACE nozzle(s) as
outlined under On
Bench Injection Nozzle
Testing.
C2 I CYLINDER COMPRESSION CHECK
Perform cylinder compression test as outlined. @) ~ GO to Engine

procedure.
r$J ~ GO to IC31.
C3 I CHECK CRANKCASE PRESSURE
Perform Engine Performance Diagnosis procedure

Test Step EPC.11 B.
@) ~ SERVICE valve train as
necessary.. REFER to
22-12.
r$J ~ OVERHAUL problem

cylinder(s). REFER to
22-12.

ALL RIGHTS RESERVED
IExcessive Black Smoke Pinpoint

Test
D
DO I VERIFY SMOKE LEVEL
Verify under what conditions black smoke occurs. Light load or ~ GO to [QI].
low altitude
NOTE: Excessive black smoke. may be NOTE: For warranty
accompanied by poor performance or low claim approval,
power. Engine Performance
Chart must be filled
NOTE: Refer to Symptom Analysis. out.
Under heavy ~ A certain amount of

load black smoke is normal
when going up steep
grades, under maximum
load, maximum boost,
maximum acceleration
or at high altitude.
01 I EXHAUST RESTRICTION CHECK
Inspect exhaust system for kinks or restriction. @) ~ GO to 1021.

Disconnect exhaust system at turbo and check
performance. fh ~ SERVICE or REPLACE
exhaust system
components as
necessary. REFER to
26-01.
02 I CHECK AIR INTAKE RESTRICTION
Perform Engine Performance Diagnosis Test Step @) ~ GO to 1031.

EPC.7.
fh ~ REPLACE air filter or

other components as
required.

ALL RIGHTS RESERVED
Diesel Diagnosis ~ 6.6L and 7.8L Ford Diesel Engines 1925
Pinpoint
IExcessive Black Smoke Test
D
03 I CHECK STATIC TIMING

'.
Check static engine timing as

manual.
o~tlined in this ~ GO to Engine
Test Step IEPC.10 I.
f/!J ~ Set static engine timing

as outlined in this
manual.
04 I CHECK NOZZLE FUEL DELIVERY

restrictions.
~ GO to IEPC.111.
Perform On-Vehicle Injector Nozzle test as

outlined.
f/!J ~ REPLACE restricted or
damaged line(s).
REFER to Shop
.,
WARNING I Manual, Section 25-06
or REPLACE nozzle(s)
as outlined under On
BE EXTREMELY CAREFUL TO PREVENT BEING Bench Injection Nozzle
STRUCK BY DIESEL FUEL' UNDER PRESSURE. Testing.
EASILY PIERCE THE SKIN, POSSIBLY CAUSING If problem still exists,
SEVERE SKIN POISONING. IF. STRUCK BY REPLACE the injection
DIESEL FUEL, SEEK MEDICAL HELP pump. REFER to Shop
IMMEDIATELY.
-.
NOTE: For warranty
cl.aim approval,
Engine Performance
chart must be filled
out.
00 ..
.-.
f
'0

ALL RIGHTS RESERVED
Fog-Like Exhaust (White or Blue) Pinpoint

E
In Full-Load Range Test
EO I CHECK COOLING SYSTEM
Check to see that engine is reaching operating

temperature.
~ GO to IE21.
0 ~ GO to~.
E1 I THERMOSTAT OPERATION
Remove thermostats and test for proper operation.

Refer to Shop Manual, Section 22-12.
~ GO to IE31.
0 ~ REPLACE
thermostat(s).. REFER
to Shop Manual,
Section 22-12. REPEAT
Step IEOI.
E2 I EXCESSIVE OIL LEVEL
Check engine oil level indicator for excessive oil

fill. ~ GO to IE31.
0 ~ ORAlN excess oil from

oil pan. If problem still
exists, GO to IE31 .
E3 ICHECK CRANKCASE BREATHER/ROAD DRAFT

TUBE .
.
Check for restricted crankcase breather element
or plugged crankcase road draft tube.
~ GO to IE41.
0 ~ When obstruction is
removed, RUN engine
for 30 minutes to burn
off accumulated oil in
exhaust system.
E4 I CHECK FUEL RETURN
Perform Engine Performance Diagnosis Test Step

EPC.8E. ~ PERFORM Engine
NOTE: If the fuel Injection pump overflow valve procedure.
Is stuck shut, It will simulate a clogged
fuel return line. To check this valve,
measure inlet pressure to the injection
pump. If the pressure exceeds 193 kPa
0 ~ SERVICE or REPLACE
fuel return line(s).
REFER to Shop
(28 psi) at rated rpm the valve must be Manual, Section 25-06.
removed and cleaned or replaced. Refer REPEAT Step IE31.
to Shop Manual, Section 25-06.

ALL RIGHTS RESERVED
Pinpoint
Engine Cannot. Reach Governed RPM F
Test
FO I VEHICLE OVERLOADED
Check to see if vehicle is being overloaded, Vehicle is ~ INFORM customer to

(above specified GVW). overloaded reduce loads.
Vehicle load ~ GO to [IT] .

normal
F1 I THROTILE LINKAGE
Check throttle adjustment as outlined under

Engine Performance Diagnosis Test Step EPC.3.
~ PERFORM Engine
procedure.
~ ~ ADJUST the throttle

adjustment. REFER to
25-60.
"

ALL RIGHTS RESERVED
Pinpoint
IEngine Knocks Test
G
GO I VEHICLE OVERLOADED
Check to see if vehicle is being overloaded Vehicle is ~ INFORM customer to

(above specified GVW). overloaded reduce load.
Vehicle load ~ GO to IG11.

normal
G1 I BELT DRIVE ACCESSORIES
Check engine front drive components for proper

operation.
@) ~ GO to IG21.
components as
necessary. REFER to
specific accessory
Shop Manual Section.
G2 I ENGINE COOLANT TEMPERATURE
Verify engine coolant temperature is below 105C

(220F).
@) ~ GO to IG31.
~ ~ GO to Pinpoint Test Q.
G3 I ISOLATE ENGINE KNOCK
Loosen each injector nozzle line nut (one at a Engine knock ~ GO to Engine
time) while running engine. not isolated to Performance Diagnosis
I WARNING I specific cylinder procedure.
BE EXTREMELY CAREFUL TO PREVENT BEING Engine knock ~ GO to IG41.

STRUCK BY DIESEL FUEL UNDER PRESSURE. isolated to
DIESEL FUEL AT INJECTION PRESSURE CAN specific
EASILY PIERCE THE SKIN, POSSIBLY CAUSING cylinder(s)
DIESEL FUEL SPRAY, SEEK MEDICAL HELP
IMMEDIATELY.
G4 I CHECK NOZZLE FUEL DELIVERY

restrictions.
@) ~ GO to Engine
Perform injector nozzle test as outlined under On procedure.
Bench Injector Nozzle Testing.
restricted or damaged
line(s). REFER to Shop
Manual, Section 25-06
or REPLACE nozzle(s)
as outlined under On
Bench Injector Nozzle
Testing.

ALL RIGHTS RESERVED
Diesel Diagnosis - 6.6L and 7.8L Ford Diesel Engi~es 19-29
ITurbocha~ger Noisy Pinpoint

Test
H
HO I AIR INTAKE OBSTRUCTION
Check for obstruction or restriction in: .@) ~ GO-to [HI].
~
a. Duct between air cleaner and compressor inlet
~ REMOVE obstruction or
b. Duct between the compressor outlet and intake REPLACE damaged
manifold parts. REFER to Shop
c. Intake manifold
H1 I AIR INTAKE LEAKS
Check for air leaks in: @). ~ GO to IH21.
~
a. Duct between the air cleaner and compressor
inlet ~ REPLACE seals or
. tighten fasteners.
b. Duct between the compressor outlet and intake REFER to Shop.
manifold Manual, Section 22-12.
c. Intake manifold to engine connection
d. Air cleaner housing and element
H2 I EXHAUST SYSTEM RESTRICTION
Check for restricted or damaged exhaust system. @) ~ GO to IH31.
exhaust system
26-01.
H3 I EXHAUST GAS LEAK
Check for ex~aust gas leak at: @) ~ GO to IH41.

a. Exhaust manifold-to-engine connection
b. Turbine inlet to exhaust manifold ~ ~ REPLACE gaskets or
TIGHTEN fasteners.
REFER to Shop
c. Turbine hou'sing to center housing
d. Turbine outlet to exhaust pipe

ALL RIGHTS RESERVED
19-30 Diesel Diagnosis - 6.6l and 7.8l Ford Diesel Engines
Pinpoint
ITurbocharger Noisy Test
H
H4 I COMPRESSOR WHEEL
Check for dirt caked on turbocharger compressor

wheel or obvious signs of foreign object ingestion.
~ GO to IHSI.
NOTE: If there is damage to compressor wheel

or turbine wheel, the turbocharger will
~ ~ CLEAN the compressor
wheel with a non-
caustic cleaner and
have to be replaced.
soft brush. FIND and
CORRECT source of
unfiltered air. CHANGE
engine oil and oil filter.
H5 ITURBOCHAR~ER
Remove turbocharger from engine. Check

turbocharger for damage. Perform bearing
~ INSTALL turbocharger
on enQine. GO to Step
clearance inspection. Refer to Shop Manual, IEPC.121.
Section 25-45.
~ ~ REPLACE turbocharger.
REFER to Shop

ALL RIGHTS RESERVED
Turbocharger Noisy or Cyclic Pinpoint

J
Sound From Turbocharger Test
JO I AIR INTAKE DUCT
Check for a restriction in air intake duct into turbo

compressor inlet.
GO to QIJ .
r#J ~ REMOVE obstruction or

REPLACE damaged
parts. REFER to Shop
J1 I COMPRESSOR WHEEL
Check for dirt caked on compressor wheel of

turbocharger.
GO to Pinpoint Test
Step IHSI.
r#J ~ CLEAN compressor

wheel with a non-
caustic cleaner and a
soft brush. LOCATE
,
and CORRECT source
of unfiltered air.
CHANGE engine oil
and oil filter.
.
~

ALL RIGHTS RESERVED
Oil Leak From Turbocharger Pinpoint

K
Compressor Or Turbine Seal Test
TEST STEP RESULT ~ ACTION TO TAKE'
KO I CHECK AIR INTAKE RESTRICTION
Perform Engine Performance Diagnosis Test Step

EPC.7.
@) ~ GO to [K!].
~ ~ REPLACE air filter or

other components as
needed. REFER to
25-40.
K1 I EXHAUST SYSTEM RESTRICTION
Inspect exhaust system for kinks or restriction. @) ~ GO to IK2/.

Disconnect the exhaust system at the turbo and
check performance.
exhaust system
components as
necessary. REFER to
26-01. ,
K2 I EXHAUST GAS LEAK
Check exhaust manifold-to-engine gaskets for

leaks at ports.
@) ~ GO to IK31.
~ ~ REPLACE exhaust
manifold-to-engine
gasket(s). REFER to
22-12.
K3 I CHECK TURBINE INLET
Check turbine inlet-to-exhaust manifold gasket for

leaks.
@) ~ GO to IK41.
~ ~ REPLACE exhaust
manifold-to-turbocharger
gasket. REFER to
22-12.
K4 lOlL DRAIN LINE OBSTRUCTION
Check oil drain line for restriction. @) ~ GO to IKSI.
oil drain line. REFER
to Shop Manual,
Section 25-45.

ALL RIGHTS RESERVED

K
K5 I CRANKCASE VENT OBSTRUCTION
Check crankcase vent tube for damage or @) ~ GO to IK61.

restriction.
crankcase vent tube.
REFER to Shop
KG I TURBOCHARGER CENTER HOUSING
Check turbocharger .center housing for sludge or @) ~ GO to IK71.

coke deposits.
~ ~ CHANGE engine oil

and oil filter. REPLACE
turbocharger, if
necessary. REFER to.
25-45.
K7 I EXCESSIVE BLOW-BY
. Perform Engine Performance Diagnosis procedure @) ~ GO to IKS/.

Test Step EPe. 11 B.
~ ~ SERVICE engine as
required. REFER to
22-12.
K8 I INTERNAL ENGINE PROBLEM
Perform compression test as outlined. @) ~ GO to IK91.
required. REFER to
22-12.

ALL RIGHTS RESERVED

K
K9 I COMPRESSOR WHEEL
Check for dirt caked on turbocharger compressor @) ~ GO to IK101.

or turbine wheel for obvious signs of foreign
object ingestion.
NOTE: If there Is damage to compressor wheel
~ ~ CLEAN compressor
wheel with a non-
caustic cleaner and
or turbine wheel, the turbocharger will soft brush. FIND and
have to be replaced. CORRECT source of
unfiltered air. CHANGE
engine oil and oil filter.
K10 I TURBOCHARGER
Check turbocharger for damage. Perform failure @) ~ CHECK for oil leakage
from other sources.
analysis: Refer to Shop Manual, Section 25-45.
REFER to Shop

ALL RIGHTS RESERVED
Low Oil Pressure With Proper Pinpoint

L
Oil Level Test
. TEST STEP RESULT ACTION TO TAKE
lO I CHECK OIL PRESSURE
Remove oil pressure sending unit. Connect CHECK oil pressure

Rotunda Pressure Test Kit 014-00762 or gauge and I or sending
equivalent 11706 ~o engine. Refer to Pressure unit. REFER to Shop
Test. Kit Hook-up, Figure 20. Manual, Section 33-32.
Run engine until normal operating temperature is
reached and check oil pressure. INSTALL sending unit.
GO to UJJ.
. Engine oil pressure should be 103 kPa (15 psi)
minimum at Low Idle - 65-95 psi (488-655 kPa) at
High Idle. '
l1 I CHANGE ENGINE OIL AND FILTER
Change engine oil and filter. Use engine oil that RETURN vehicle to
meets API specification: SGICE (recommended), customer.
SF ICE or CEo Determine viscosity. according to
ambient temperature. GO to IL21.
C F
... 38 ... 100 4 ~_..J >
... 16 ... 60-----~
... 5 ... 40
o ... 32
-7 ... 20
-12 ... 10 - - - ---------

SAE 15W-40
-18 0---1---------- -s;.';:;w-so

(PREFERRED)
- 29 - 20 - -sAE 5W30

OUTSIDE
TEMPERATURE
A11604B

reached.
Check oil pressure reading.

ALL RIGHTS RESERVED
Low Oil Pressure With Proper Pinpoint

L
Oil Level Test
L2 I CHECK OIL PUMP DRIVE GEARS
Remove oil pan. . @) ~ GO to IL31.

Check oil pump drive gears for damage or wear.
Check drive gear backlash. Refer to Shop Manual,
f/!J ~ REPLACE oil pump
drive gears. REFER to
Section 22-12. Shop Manual, Section
22-12.
L3 I CHECK OIL PUMP INLET TUBE
Check oil pump inlet tubes for cracks. @) ~ GO to IL41.

Check that oil pump inlet tube attaching bolts are
tightened to specification. Refer to Shop Manual, f/!J ~ REPLACE oil pump
inlet tube or TIGHTEN
Section 22-12.
attaching bolts to
22-12. CHECK engine
oil pressure.
L4 I CHECK OIL PRESSURE TUBE
Check oil pressure tube for cracks. @) ~ SERVICE or REPLACE

oil pump assembly as
Check that oil pressure tube attaching bolts are necessary. REFER to
tightened to specification. Refer to Shop Manual, Shop Manual, Section
Section 22-12. 22-12.
f/!J ~ REPLACE oil pressure

tube or REPLACE oil
pressure tube-to-engine
block gasket and
TIGHTEN attaching
bolts to specification.
REFER to Shop

ALL RIGHTS RESERVED
Pinpoint
Excessive Oil Consumption M
Test
TEST STEP RESULT ~' ACTION TO TAKE
MO I LEAK CHECK
Visually inspect for external oil leaks. @)" ~ GO to IM11.
~ ~ SERVICE 'oil leaks.

RETURN vehicle to
customer.
M1 I CHECK AIR INLET SYSTEM
Check for air cleaner restriction and check air'

induction system for leaks. Perform Engine
@) ~ GO to IM21.
~
Performance Diagnosis Test Step EPC.11 B.
~ SERVICE or REPLACE
air inlet system
components. "REFER to
- Shop Manual, Section
22-12.
M2 I VERIFY PROBLEM
Change the oil. Use oil that meets API Oil consumption ~ RETURN vehicle to
specification: SG/CE (recommended), SFICE or less than 0.95L customer. Oil
CEo Determine viscosity according to ambient (1 quart) per consumption is normal.
temperature as shown on chart in Pinpoint Test 483 km (300
Step L 1. miles)
Determine oil consumption rate and trend at: 1610
km (1000 miles/50 hours) or 8047 km (5000 Oil consumption ~ GO to IM31.
miles/250 hours). more than 9.5L
Record amount of make-up oil added during test (1 quart) per
period. 483 km (300
miles)
M3 I CHECK VEHICLE LOAD
Determine if abnormally heavy loads are being Vehicle load ~ GO to IM41.

pulled by vehicle (above specified GVW). normal
Vehicles ~ INFORM customer to

overloaded reduce loads.
M4 I CHECK VEHICLE OPERATION
Check for improper operation (i.e., allowing engine Truck being ~ GO to'1 Msi.
to lug in incorrect gear range) resulting in oil driven correctly
consumption.
Engine being ~ INFORM customer to
lugged REV~EW operator
habits to be sure
engine is not being
lugged.

ALL RIGHTS RESERVED
1938 Diesel Diagnosis - 6.6l and 7.8l Ford Diesel Engines
Pinpoint
Excessive Oil Consumption M
Test
M5 I CHECK AIR CLEANER RESTRICTION
Perform Engine Performance Diagnosis Test Step Air cleaner ~ GO to IM61.

EPC.7. Restriction should be less than 2.5 kPa restriction within
(10 in) H2O. specification
Pulls over oil ~ REPLACE element.

through REPEAT IMsi.
turbocharger
compressor
seal
M6 ICHECK CRANKCASE BREATHER/ROAD DRAFT

TUBE
Check for restricted crankcase breather element

or plugged crankcase road draft tube.
@)-~ GO to IM71.
Check crankcase pressure step EPC.11 B.

breather element or
vent. RUN engine for
30 minutes to burn off
accumulated oil in
exhaust system.
M7 I CHECK AIR COMPRESSOR
Check air compressor for worn rings causing oil

to leak into air system. Refer to Shop" Manual,
@) ~ GO to IMSI.
Section 12-40.
air compressor. REFER
to Shop Manual,
Section 12-40.
M8 I CHECK VALVE GUIDES/SEALS
Check for worn engine valve guide seals or valve

guides. Refer to Shop Manual, Section 22-12.
@) ~ GO to IM91.
0 ~ CLEAN, INSPECT and

REPLACE as
necessary. REFER to
22-12.
M9 I CHECK COMPRESSION
Perform engine compression test as outlined. @) ~ RETURN vehicle to

customer.
. 0 ~ SERVICE engine as
necessary. REFER to
."
22-12.

ALL RIGHTS RESERVED
Pinpoint
Fuel Dilution in Lubricating Oil N
Test

..
NO I VERIFY THE PROBLEM
Determine if there is fuel present in lubricating oil. No dilution

-.
~ RETURN vehicle to
customer.
NOTE: If fuel is present, oil will have the odor
of diesel fuel.
Fuel diluted ~ CHECK to see if
vehicle has been idled
for excessive periods.
CHECK for internal fuel
injection pump or
injection nozzle
leakage. REFER to
25-06.
. . "'
..
.'

ALL RIGHTS RESERVED
Excessive Coolant Temperature Pinpoint

P
Temperature Above 105C (220~F) Test
PO I VERIFY CONDITION
Determine conditions when overheating .occurs. Ambient ~ INFORM customer that

NOTE: Ambient temperatures above 43e (110F) temperature condition is normal.
may cause engine temperatures to above 43C
exceed 10Soe (220F). (110F)
Ambient ~ GO to~.
temperature
below 43C
(100F)
P1 I VERIFY OPERATION
Check operator's driving habits (running in

improper gear ranges, etc).
@) ~ GO to Ip21.
~ ~ INFORM customer to
REVIEW operator
driving habits.
P2 I CHECK ACCESSORIES
Check that all accessory equipment is approved. @) ~ GO to Ip31.

Check accessory drive belt tension. Refer to Shop
~ ~ ADJUST belt tension or
REPLACE belts.
INFORM customer
accessories are not
approved.
P3 I CHECK ENGINE
Check that engine is clean. @) ~ GO to Ip41.

Check for engine coolant and/or oil leaks.
~ ~ CLEAN engine.
SERVICE engine
coolant and/or oil
leaks as necessary.
P4 I CHECK ENGINE COOLANT
Check coolant condition. Refer to Shop Manual,

Section 27-02.
@) ~ GO to Ipsi.
~ ~ DRAIN, FILL and

BLEED the coolant
system using the
specified coolant and
coolant conditioner.
REFER to Shop

ALL RIGHTS RESERVED
Diesel Diagnosis - 6.6l and 7.8l Ford Diesel Engine's 1941
Excessive Coolant Terilperature Pinpoint

P
Temperature Above 105C (220 P) 0
Test
P5 I CHECK RADIATOR, HOSES, CLAMPS
Check radiator cap for proper operation. @) ~ GO-to" P61.
~)~
Check that correct hoses are installed and are
properly c,lamped. SERVICE or REPLACE
components as
Check that radiator is correct for vehicle and is necessary. REFER to
clean and unobstructed by bent fins, pinched Shop Manual, Group
tubes or foreign objects. 27. ,.
Check that correct fan is properly installed. . '
P6 I CHECK WATER PUMP
Check water pump for worn bearings or coolant @) ~ 'GO to Ip71.

leaks.
f/j ~ SERVICE or REPLACE
water pump. REFER to
, 22-12.
P7 I CHECK THERMOSTATS
Check thermostats for proper operation. Refer to @) ~ GO to Ipsi.

Shop Manual, Section 22-12.
f/j ~ REPLACE thermostats.
REFER to Shop
P8 I CHECK STATIC TIMING
Check injection pump static timing as outlined. @) ~ GO to Ipgl.
f/j ~ ADJUST static timing

as outlined.

ALL RIGHTS RESERVED
Excessive Coolant. Temperature Pinpoint

P
Temperature Above 105C (220F) Test
I CHECK
P9 FOR BLOWN HEAD GASKET
Fill a bucket and suitable bottle with water. No bubbles

present
. GO to Ip101.
reached. Stop engine.
Place filled bottle in bucket with neck facing
down.
Bubbles present . REPLACE blown head
gasket. REFER to
22-12.
Insert coolant overflow hose into neck of bottle.
Start engine and look for air bubbles in bottle.
P10 ICHECK COOLING SYSTEM FOR
.
CONTAMINATION
No RETURN vehicle to
contamination customer.
present
Contamination
present
. CLEAN cooling system.
REFER to Shop

ALL RIGHTS RESERVED
Pinpoint ..Q
Fuel Injection Pump Overheating
Test
QO I OVERFLOW VALVE . '
Verify that "fuel flows freely from overflow valve. ) ~" PERFORM Engine
Test Step IEPC.8E I.
CV!J ~ CLEAN orifice in

overflow valve or
REPLACE fitting.
REFER to Shop
'.
~
r
. .. :
. .

ALL RIGHTS RESERVED
19-44 Diesel Diagnosis - 6.6l and 7.8l Ford Diesel Engines
Engine Performance Diagnosis Procedure
The Engine Performance Diagnosis procedure begins with those items which are the high
frequency, easy-to-diagnose problems, and progresses to the low frequency, hard-to-diagnose
problems. Use of this procedure will promote rapid, as well as accurate diagnosis.
The Engine Performance Diagnosis procedure follows, step-by-step, the Engine Performance
Chart. Each test step is labeled to coincide with the Engine Performance Chart steps.
NOTE: Under no circumstances should the fuel injection pump, fuel injectors or
turbocharg~r be replaced until the Engine Performance Chart has been
completely filled out. Warranty claims for the fuel injection pump, fuel injectors
and turbocharger will not be accepted unless the Engine Performance Chart has
been filled out as specified and all tamper-proof seals are intact.
Service each problem detected before going on the next step. If service corrects the original
complaint, it will not be necessary to proceed to the next test step. However, if the complaint
is not corrected, continue with the procedure until the complaint is corrected.
The following explanations refer to the basic test steps of the Engine Performance Diagnosis
procedure and Chart. They give a brief description of the effect on performance these
problems can create, giving an understanding of the importance of each test step.
1. External leakage: Fuel leakage can be a reason for diesel fuel smell, poor fuel economy
or poor performance. Oil leakage can be a reason for high oil consumption. An air intake
system leak can shorten engine and turbocharger life, especially under dusty conditions.
Coolant leakage can result in engine overheating. Exhaust gas or boost air leakage can
cause poor engine performance and black smoke.
2. Exhaust System Condition: Kinks or dents in the exhaust system can cause high
exhaust back pressure. This can result in loss of power and high smoke levels. If an
aftermarket exhaust brake is installed ensure:
Maximum exhaust pressure does not exceed 310 kPa (45 psi) @ 2860 rpm.
Exhaust brake assembly is mounted a minimum of 1.7m (5.5 ft) downstream from
turbocharger.
3. Accelerator Linkage: If the accelerator linkage is improperly adjusted, damaged or worn,

low idle speed may be out of specification and the engine may not reach high idle and
top speed, causing pulling power to be reduced.
4. Fuel System Condition: Kinks in the fuel lines or hoses can block or restrict fuel flow
and loose connections can leak air into the fuel. This can result in loss of power, high
smoke levels and failure to start.
5. Fuel Quality: Diesel engines need clean fuel, free of air, dirt, water and microbiological
organisms. Any contamination may result in poor engine performance.
NOTE: If the fuel is contaminated with water, microbiological organisms are able to
grow in a diesel fuel tank, especially in warm, moist climates. Therefore, it is
very important to keep water from getting into the fuel.

ALL RIGHTS RESERVED
The diesel fuel recommended for use in the 6.6L and 7.8L Ford Diesel engines must be
either grade 1-0 or 2-D. Use No. 2-D fuel when ambient temperatures are above - 7C
(20F). Use No. 1-0 when ambient temperatures are below' - 7C (20F). If No. 1-0 is not
available, use winterized 2-D. Use of regular No. 2-D during. cold weather may cause
starting and/or driveability problems due to reduced fuel flow caused by fuel waxing.
The use of high sulfur fuel should be avoided. When fuel sulfur content exceeds 0.5
percent by weight, oil change intervals should be shortened. Consult the maintenance
schedule for the requJred intervals.
6. Engine Idle Speed: Low engine idle speed may cause stalling or "rough running.
7. Air Cleaner Restriction: A dirty air filter or restriction in the air cleaner may result in low
power, excessive smoke, poor fuel economy and oil leakage from the turbocharger.
8. Fuel System Pressure and Capacity: The fuel supply system must deliver the proper
quantitY of fuel with no pressure loss or air leaks in the chassis fuel system and then
return unused fuel to the fuel tank. Restriction in the lines providing fuel to the fuel
injection pl;Jmp will result i~ low' power, smoke problems and generally poor performance.
Restrictions in the lines returning fuel to the fuel tank may cause problems of injection
pump <;>Verheating, smoke problems and generally poor performance.
9. Injection Timing: Incorrect timing can be responsible for poor fuel economy, rough idling,
hard starting and excessive smoke. Injection timing can be checked either statically or
dynamically but can only be set statically.
10. The injector nozzles must be removed from the engine for testing. This is a functional test
of injector nozzle performance which checks opening pressure, spray pattern and leakage.
. "
11. Compression and Crankcase Pressure: These tests examine the condition of internal
components of the engine. Low compression indicates leakage past the piston rings or
valves. Crankcase pressure measures the amount of blow-by past the rings. Excessive
blow-by past the rings creates high pressure in the crankcase. The crankcase pressure
test will also indicate a clogged crankcase ventilation system. Compression testing,
crankcase pressure readings and rate of oil consumption should be used to evaluate
engine mechanical condition.
12. Turbocharger: These tests and checks examine the condition of the turbocharger to
determine if it is affecting engine performance. Problems which can be caused by a
turbocharger include low power,excessive exhaust smoke, excessive engine oil
consumption, noise and oil leaks. Most turbocharger checks are performed with the engine
off. Boost pressure, although .not inclUded in the Engine Performance Section, can be
checked, but it requires a dynomometer since ~ full load condition must be simulated.
Specifications for turbocharger boost are given in the Engine Performance Specifications
Section and an adapter is available with the pressure test kit for checking boost pressure.
To perform the Engine Performance Diagnosis procedure, it is necessary to connect the

Rotunda Pressure Test Kit 014-00762 or equivalent (Figure 20). Use the explanations outlined
under Pressure Testing With the Gauge Bar to help in attaching the gauges and interpreting
the readings.

ALL RIGHTS RESERVED
( OIL PRESSURE I
~
ADAPTER
11950
-'~~=REI
TESTIG
LrSERIES 240 HP SHOWN
SENDING UNIT
I
F-lrSERIES
240 HPSHOWN
FILTER INLET AND

OUTLET PRESSURES
TESTS 8A AND 88
PLASTIC
LINE
ADAPTER
11996
AIR TO AIR,INTEACOOLED
~
RESTRIC1lON
INDICATOR TAP ~ft~,
CAUTION:
DO NOT CONNEcr BOTH POR1'S OF
THE MAONEHEUCGAUOE AT ONCE.
WHEN TAKING A READING (VACUUM OR
PRESSURE), LEAVE THE arHER PORT OPEN DIPSTICK
TO THE ATMOSPHERE. ALWAYS PURGE AIR TUBE NON-INTERCOOLED
BEFORE MAKING ANY FUEL LINE HOOKUP. ...PRES8URE-===.;,;TEST~.;.;;KIT;.;..:.:HOOK==U~P ,, ~ A12678-B
Figure 20 Connecting the Rotunda Pressure Test Kit

ALL RIGHTS RESERVED
Diesel' Diagnosis - 6.6L and 7.8L Ford Diesel Engines' 1947
Engine Performance Diagnosis: Procedure
6.6l and 7.8l Diesel Engines

Performance Diagnosis Procedure
Press4re Testing With the Gauge Bar
The gauge bar is used for several different pressure checks (Figure 21). Hookups are made
using special adapters manufactured specifically for the 6.6L and 7.8L Ford Diesel engines.
. - ,.
NOTE: Use of the gauge bar is not mandatory. Individual gauges can be used, as long
as they are accurate and applicable. to a particular check. Technicians who own
their own set of gauges may find that buying 'the ,Adapte~ Kit 01400733 and
01400742 will make it easier~ to hook their gauges into the 6.6L and 7.8L Ford
Diesel engines and systems.
, '
1987 and Forward 6.6L and

1986 6.6L (Phase I)
7.8L
01900034 Gage Bar Kit 014-00762
NU-12094 Lift Pump Inlet Adapter 014-00742-2
NU-11950 Fuel Return Adapter NU-12094
NU-5643 Turbo Boost Adapter NU-5643
NU-5650 Air Filter Adapter NU-5650
NU-11995 CD Fuel Line-Lift Pump-to-Filter NU-11995
Inlet Adapter
NU-11996 Fuel Line-Filter Outlet-to-Injection N'U-11996
Pump Adapter
NU-11706 Oil Pressure Adapter : NU-11950
NU-11949 Crankcase Pressure Adapter 014-00742-1
CD Adapter Kit 019-00033
Adapter Kit 014-00733 t ....
Adapter Kit 014-00742",

\
NOTE: Adapter Kits 01400733 and 01400742 may be used with any previously released
pressure Test Kit (Gauge Bar).
Figure 21 Pressure Checks using 'Gauge Bar

ALL RIGHTS RESERVED
Diagnostic tests that can be accomplished with the gauge bar along with hookup instructions
are listed here:
Filter Inlet Pressure: Filter inlet pressure is measured by disconnecting the fuel line between
the lift pump and the fuel filter inlet. In its place, a plastic line (11995) from the pressure test
kit is installed. This line is equipped with aT-connection so that a pressure tap to the gauge
bar can be made. Attach a line from the T-connection to the 0-1103 kPa (0-160 psi) gauge.
Filter Outlet Pressure: Filter outlet pressure is measured by disconnecting the fuel line
between the fuel filter outlet and the inlet to the fuel injection pump. In its place, a plastic line
(11996), from the pressure test kit is installed. This line is equipped with aT-connection so
that a pressure tap to the gauge bar can be made. Attach a line from the T-connection to the
0-206 kPa (0-30 psi) gauge.
Connect both the Filter Inlet and Filter Outlet Pressure adapters at the same time to check
the following:
Filter Inlet Pressure
Filter Outlet Pressure
Pressure Drop Across the Fuel Filters
Lift Pump Output Pressure
Injection Pump Inlet Pressure (Fuel Galley Pressure)
Air Leaks in the Fuel System (look for air bubbles in the plastic fuel lines)
Lift Pump Inlet Suction: To measure lift pump inlet suction, the coupling for the fuel line
going into the fuel box from the fuel tank must be disconnected. At this point an adapter is
screwed into the fuel box coupling and the fuel line coupling is screwed into the adapter. The
adapter is equipped with a pressure tap which must be connected to 1-30 in Hg/0-15 psi
gauge.
Fuel Return Line Pressure: To measure fuel return line pressure, the coupling for the fuel
line going out of the box to the fuel tank must be disconnected. At this point, adapter 12094
is screwed into the fuel box. The adapter is equipped with a pressure tap which must be
connected to the 0-1 bar (0-103 kPa or 0-15 psi) gauge.
011 Pressure: Oil pressure is checked by tapping into a flexible line between the oil filter
support and oil pressure sender switch. Use adapter 11950 to attach to either a coupling in
the line or at the oil pressure sender switch at the dash panel.
Air Filter Restriction: Air filter restriction is checked at the same port where the restriction
indicator is located. To check ajr fjlter restriction, remove the restriction indicator and install
the adapter (5650) from the pressure test kit in its place. Connect the adapter to the vacuum
side of the magnehelic gauge.

ALL RIGHTS RESERVED
Crankcase Pressure: Crankcase pressure is measured from the 'dipstick tube. To make this
check, remove the dipstick and install the adapter (014-00742) from the pressure side of the
magnehelic gauge.
i CAUTION 1
Do not connect both parts of the magnehelic gauge at once. When taking a reading
(vacuum/pressure) leave the other port open to the atmosphere.
Turbo Boost Pressure: Turbo boost pressure' is measured from a tap on the crossover tube
or inlet manifold. Remove the tap and install the adapter (5643) from the pressure test kit.
Connect the adapter to the 0-206 kPa (0-30 psi) gauge.
NOTE: Turbo boost pressure is checked only on a dynomometer or where full load
conditions can be simulated.
Air Leak Testing
The gauge bar is equipped' with a pressure pump. This pump can be used to pressurize fuel
lines to help locate air leaks. Once an air leak is verified by seeing air' bubbles in the fuel
going to the injection pump, the exact location can be determined using the pressure pump
and the following procedure:
1. Plug the en~ of the fuel line.
2. Install the pump into the system in front of the suspected air leak.
3. Pressurize the system to a maximum of 104 kPa (15 psi) and maintain pressure.
,4. Wipe the fuel Jines and connections with a _soap and water solution.
5. An air leak will show up as bubbles.
6. Tighten the cornection or replace components as needed to eliminate the leak.
Checking Fuel Cetane
Checking fuel is very important in diagnosis. Contaminants in the fuel, like water and
microbiological organisms, are easy to see when a fuel sample is placed in a clear container.
Diesel fuel should be clear, with an amber t'int (actual color may vary). Water or particulates
floating in the fuel are indicators of contaminated fuel. D,iesel fuel must have a cetane rating
of at least 40.

ALL RIGHTS RESERVED
Pinpoint
Engine Performance Diagnosis EPC
'Test
EPC.11 CHECK FOR EXTERNAL LEAKAGE
With engine running, visually check for leakage of: @) ~ GO to IEPC.21 .

1. Fuel
2. Engine oil 0 ~ SERVICE or REPLACE
faulty component(s). If
performance problem
3. Dirt past air cleaner
still exists, GO to
4. Coolant IEPC.21.
5. Exhaust
6. Boost air
EPc.21 CHECK EXHAUST SYSTEM
Visually check exhaust system for dents or kinks @) ~ GO to IEPC.31.

which could cause restriction.
exhaust system
components as
required. REFER to
26-01. GO to IEPC.31 .
EPC.3! ACCELERATOR LINKAGE

ADJUSTMENT
With engine off, check that control lever contacts

injection pump stops. Control lever must contact
@) ~ GO to IEPC.41.
low idle stop when accelerator pedal is released,
and must contact high idle stop when accelerator
is fully depressed.
0 ~ ADJUST or SERVICE
vehicle throttle linkage
as necessary. REFER
to Shop Manual,
Section 25-60. GO to
IEPC.41.
"
EPC.41 FUEL SYSTEM CONDITION
Inspect fuel supply and return lines and hoses for @) ~ GO to IEPC.5A I.
kinks, and all connections for tightness.
NOTE: If problem is "not starting", perform
EPC.5A and EPC.5B.
loose or damaged
component(s). If
performance problems
still exist, GO to
IEPc.5AI.

ALL RIGHTS RESERVED
Dles.el Diagnosis - 6.6L and 7.8~ Ford Diesel Engines 1951
Pinpoint
Test
EPC.5AI CHECK FUEL FOR CONTAMINATION
@) .
fh .
Obtain a fuel sample and visually examine fuel in GO to IEPC.61.
a clear container (including bottom of container),
for particles, clouding, or liquid contamination, REPLACE engine and
such as water. chassis fuel filters.
CLEAN and/or
"
SERVICE fuel system.
REFER to Shop
GO to IEPC.61 .
EPC.61 CHECK ENGINE IDLE SPEED
.@) .
fh .
Check engine speed as outlined under GO to IEPc.71.
Adjustments.
Bring engine up to normal operating temperature. ADJUST idle speed as
outlined in this Section.
Idle speed is measured with manual transmission GO to IEPC.71.
in NEUTRAL and automatic transmission in PARK.
Idle speed is shown on Vehicle Emission Control
Information decal (VECI).
EPC.71 CHECK AIR INTAKE RESTRICTION
Remove air cleaner restriction indicator and install

adapter 5650 and Rotunda Pressure Test Kit 014-
00762 or equivalent. Refer to Figure 20.
@) . REMOVE adapter.
INSTALL cap on air
cleaner port. GO to
fh .
IEPc.8AI.
Run engine at rated rpm, no load.
. .
Record restriction reading. REPLACE filter element
and CHECK intake
Restriction should not exceed 2.5 kPa system for blockage.
(10 in of H2O). REPEAT IEPC.71. If
restriction indicator is
not functioning .
correctly, REPLACE it.

ALL RIGHTS RESERVED
Pinpoint
Test
EPC.8AI FUEL FILTER OUTLET PRESSURE

Install adapter 11996 with Rotunda Pressure Test
Kit 014-00762 or equivalent. Refer to Figure 20. ~ GO to IEPC.8C I.
Run engine at rated rpm with no load, Fuel pressure ~ GO to IEPC.8B I.
transmission in PARK or NEUTRAL. too
Record pressure reading. low or fuel
does
Pressure should be 103-193 kPa (15-28 psi) at not appear
rated rpm.
Fuel pressure ~ GO to IEPC.8G I.
too high
EPC.8BI FUEL FILTER INLET PRESSURE
Install adapter 11995 with Rotunda Pressure Test

Kit 014-00762 or equivalent. Refer to Figure 20. ~ GO to IEPC.8C I .
Run engine at rated rpm with no load, Pressure drop ~ REPLACE fuel filters.
transmission in PARK or NEUTRAL. is greater than REPEAT IEPc.8sl.
Record pressure reading. 48 kPa (7 psi)
Pressure should be 103-207 kPa (15-30 psi) with
a maximum allowable pressure drop across the Pressure is ~ GO to IEPC.8C I.
filter of 48 kPa (7 psi). below
103 kPa (15
psi)
EPC.8CI CHECK FUEL SYSTEM FOR AIR LEAKS

Run engine with adapters 11995 and 11996 No bubbles ~ GO to IEPC.8E I.
installed, and observe clear plastic lines for air present
bubbles.
Bubbles present ~ GO to IEPC.8D I.
EPC.801 CHECK CHASSIS FUEL LINES

.
Disconnect fuel supply line at engine and fuel Bubbles present ~ SERVICE or REPLACE
tank. any leaking connection
Plug one end of line and connect pressure pump or fittings. REFER to
from Rotunda Pressure Test Kit 014-00762 or Shop Manual, Section
equivalent to other end of line. Refer to Figure 25-50. REPEAT
, 20. IEPC.8CI.,
,Apply a maximum of 103 kPa (15 psi) to line, and
hold pressure. No bubbles ~ SERVICE ends of fuel
present supply lines.
Apply a soap and water solution to all CHECK fuel tank
connections and fittings, and look for air bubbles. pickup for leaks.
SERVICE or REPLACE
fuel tank pickup.
REFER to Shop
REPEAT IEPC.8C I.

ALL RIGHTS RESERVED
Diesel Diagnosis - 6.6L and 7.8L Ford Diesel' Engines 1953
Pinpoint
Test
I
EPC.8E CHECK LIFT PUMP
Connect adapter 12094 and Rotunda Pressure @) ~ GO to IEPC.8F I.

Test Kit 014-00762 or equivalent to fuel box.
Refer to Figure 20.
Run engine at rated rpm with no load,
'restricted fuel SU~PIY
line. REFER to hop
transmission in PARK or NEUTRAL. Manual, Section 25-50.
Record vacuum reading. REPEAT IEPC.8E I.
Vacuum must be a maximum of 34 kPa
(10 in Hg).
I
EPC.SF CHECK LIFT PUMP VOLUME
Disconnect lift pump outlet and connect a clean

sample hose.
@) ~ GO to IEPC.8G I.
Disconnect fuel shutoff solenoid.

Place end of sample hose in clean, graduated
~ ~ REPLACE lift pump.
REFER to Shop
container and. crank engine for 30 seconds. REPEAT IEPC.8F I.
Volume should be a minimum of 0.16L
(1/3-pint) in 30 seconds or less.
I
EPC.8G CHECK FUEL RETURN PRESSURE
Disconnect fuel return line at fuel box. Install Fuel return ~ GO to IEPC.91.
adapter 11950 and Rotunda Pressure Test Kit . pressure OK,
014-00762 or equivalent. Refer to Figure 20. EPC.8A OK
"
transmission in PARK or NEUTRAL. Fuel return ~ SERVICE or REPLACE
pressure OK, injection pump overflow
Record pressure reading. 'but fuel filter valve. REFER to Shop
outlet pressure Manual, Section 25-06.
Pressure should not exceed 41 kPa in EPC.8A high REPEAT IEPC.8A I.
(6 psi) at rated rpm. ,"
Fuel return ~ SERVICE or REPLACE

pressure too fuel return line. REFER
high to Shop Manual,
Section 25-50. REPEAT
IEPC.8GI.
EPC.91 CHECK STATIC TIMING
Check injection pump static timing as outlined in @) ~ GO to IEPC.101.

this Section.
~ ~ ADJUST static timing

as outlined.
-

ALL RIGHTS RESERVED
Pinpoint
Test
EPC.10 I CHECK INJECTOR NOZZLES/LINES
Check injector nozzle lines for damage or

restriction.
~ GO to IEPC.11AI.
Remove injector nozzlps. Refer to Shop Manual,

Section 25-06.
~ ~ REPLACE damaged
lines. REFER to Shop
Test injector nozzles as outlined. CLEAN or REPLACE
injector nozzles as
outlined.
REFER to Shop
for Installation. If
performance problem
still exists, GO to
IEPC.11AI.
EPC.11AI CHECK COMPRESSION
Check engine compression as outlined. ~ GO to IEPC.11 B I.
necessary. REFER to
22-12.
EPC.11BI CHECK CRANKCASE PRESSURE
Remove engine oil dipstick and connect adapter

11949 and Rotunda Pressure Test Kit 014-00762
~ GO to IEPC.12AI.
or equivalent. Refer to Figure 20. GO to Pjinp,int Test
IE31 or M6 .
~
transmission in PARK or NEUTRAL.
~ Problem is internal to
Record pressure reading. engine. REFER to
Pressure should be a maximum of 0.7 kPa 22-12.
(3 in H20) at rated rpm.

ALL RIGHTS RESERVED
Pinpoint
Test
EPC.12AI CHECK TURBINE/COMPRESSOR

WHEELS
Visually check turbocharger turbine and @) ~ GO to IEPC.12BI.

compressor wheels for evidence of contact with
turbocharger housing (bent, broken, chipped or
eroded blades) or foreign object ingestion damage
or deposits.
0 .~ DETERMINE source of
foreign object ingestion.
SERVICE or REPLACE
turbocharger and/or
other components as
necessary. REFER to
25-45.
EPC.12BI OIL LEAKAGE-EXHAUST PIPE

ELBOW/TURBINE HOUSING
Check for oil deposits at connection between

exhaust pipe 'elbow and turbine outlet.
@).. GO to IEPC.12CI.
NOTE: Slight amount of oil seepage is normal

after extended periods of idling.
0 REPLACE turbocharger.
REFER to Shop
EPC.12CI OIL LEAKAGE-EXHAUST

MANIFOLD/TURBINE HOUSING
Check for excessive oil deposits between exhaust

manifold and turbine inlet.
@) . GO to IEPC.'12D I.
NOTE: A slight amount of oil seepage is normal

after extended periods of idling.'
0 ~ Problem is internal to
engine. REFER to
Shop Manu~I, Section
22-12.
"
EPC.12DI OIL LEAKAGE-INTAKE MANIFOLD/

COMPRESSOR HOUSING
@)
Check for oil deP9sits in intake manifold and
compressor housing.
NOTE: Slight amount of seepage is normal after
extended periods of idling.
0 .
~ GO to IEPc.12EI.
CHECK for intake
restriction. GO to
IEPc.71. If intake
restriction is OK, GO
to IEPC.12GI.

ALL RIGHTS RESERVED
Pinpoint
Test
EPC.12E lOlL LEAKAGE-OIL SUPPLYlORAIN PIPE

FLANGES
Check for oil leaks at oil supply and drain pipe @) ~ GO to IEPC.12F I.
flanges.
Check oil drain pipe for clogging. ~ ~ SERVICE or REPLACE
oil drain pipe.
TIGHTEN attaching
bolts to specification.
REPLACE gaskets as
necessary. REFER to
25-45.
EPC.12FI CHECK FOR AIR LEAKS
Visually check for air intake and exhaust leaks at

following:
@) ~ GO to IEPC.12GI.
1. Exhaust manifold to engine. a

2. Exhaust manifold to turbine inlet. a b
leaking component(s).
REFER to Shop
Manual, Sections
3. Turbine housing to center housing. ab 22-12, 25-40 and/or
4. Turbine outlet to exhaust pipe elbow. ab 25-45.
5. Compressor housing to center housing.

6. Compressor outlet to intake manifold. C
7. Compressor inlet to air cleaner duct.
8. Air cleaner housing and element.
EPC.12GI CHECK BEARING PLAY
Check turbocharger axial and radial bearing play.

Refer to Shop Manual, Section 25-45.
@) ~ REPLACE fuel injection
pump. REFER to Shop
Manual, $ection 25-06.
ADJUST static timing
as outlined.
REFER to Shop
a Possible whistle or scream noise varying with engine speed.
b May show signs of' carbon buildup.
C May cause low boost.

ALL RIGHTS RESERVED
Injector Nozzle Testing
Where ideal conditions of good combustion, specified engine temperature control, and clean
quality fuel prevail, nozzles require little attention. Nozzle trouble is usually indicated by one or
more of the following symptoms:
Exhaust smoke (black)
Low power
Missing under load
Rough warm idle
Excessive fuel consumption
Engine will not rev up
Combustion knock
Overheating
On Vehicle Testing
When faulty nozzle operation is suspected on an engine that is misfiring or puffing black
smoke, a simple test can be made. to determine the problem nozzle(s).
1. Run the engine at the rpm w~ich makes the problem most pronounced.
2. Momentarily loosen the high-pressure fuel inlet line connection on one nozzle assembly.
Listen to see if it has an effect on the engine and look to s~e if the smoke level
changes. Then tighten the connection to spe~ification. -
I WARt:lING ~
BE EXTREMELY CAREFUL TO PREVENT BEING STRUCK BY DIESEL FUEL UNDER
PRESSURE. DIESEL FUEL AT INJECTION PRESSURE CAN EASILY PIERCE THE SKIN,
POSSIBLY CAUSING SEVERE INJURY FROM BLOOD POISONING. 'IF STRUCK BY
PRESSURIZED DIESEL FUEL, SEEK MEDICAL HELP IMMEDIATELY.
3. Check each nozzle in the same manner.
, . .
4. If one nozzle is found where loosening makes no 9ifference in performance or it causes
the smoke level to change, that nozzle should be bench tested.
On ~ench Testing .
After removing the nozzle(s) from the engine, the injector nozzle pressure test should be
performed. This test will provide valuable information regarding the condition of the nozzle(s).
A clean workbench, clean washing fluid containers. clean tools and clean hands are essential
to produce satisfactory results. Injector nozzles which are not functioning properly, have
improper opening pressure, leak down, or spray patterns, should be replaced. Replacement
injectors should be tested before assembly t~ engine.

ALL RIGHTS RESERVED
Figure 22 shows the Rotunda Injector Nozzle Tester 014-00300, used for pressure testing the
injector nozzles. Use the following procedure for testing the injector nozzles.
A8942-8
Figure 22 Injector Nozzle Tester

1. Prepare the stand for making tests. Place a container partly filled with shop cloths
beneath the outlet pipe to catch the spray. Fill the stand reservoir with clean calibration
fluid. Open the tester valve slightly and operate the tester handle t9 expel the air from
the tester and outlet pipe. Operate the tester until solid fuel (no air bubbles) flows from
the end of the outlet pipe. Close the tester valve.
NOTE: Test injector nozzles using SAE approved calibration oil 208629, SAE J967D,
or ISO 4113 fluid, rather than diesel fuel.
2. Install the proper adapter for testing the 6.6L and 7.8L Ford Diesel injectors on the
injector nozzle test stand.
3. Connect the nozzle to the test stand. Take care to avoid cross-threading. Tighten
connector nut securely with a wrench.
I WARNING I
ALWAYS WEAR APPROVED SAFETY GLASSES WHEN OPERATING THE TESTER.
VOLATILE LIQUIDS CAN BE EXTREMELY FLAMMABLE WHEN VAPORIZED. AVOID
ANY CONDITIONS (SPARKS, OPEN FLAMES, LIT CIGARETTES, ETC.) WHICH MIGHT
IGNITE THE FLUID USED DURING THE TEST PROCEDURE. ENSURE THAT THE
INJECTOR IS MOUNTED ON THE TESTER SO THAT THE SPRAY IS DIRECTED AWAY
FROM THE OPERATOR AND ANY OTHER PERSONS. THE ONLY LIQUID APPROVED
FOR USE IN THIS TESTER IS SAE CALIBRATION NO. 208629 OR EQUIVALENT
CALIBRATION FLUID (SAE J967D OR ISO 4113).
WHEN A NOZZLE. IS BEING TESTED OR IS IN OPERATION, KEEP HANDS AND
OTHER PARTS OF THE BODY AWAY FROM THE SPRAYING NOZZLE. THE LIQUID
SPRAY LEAVES THE NOZZLE TIP WITH SUFFICIENT FORCE TO PENETRATE THE
SKIN AND CAUSE SERIOUS INJURY. THE NOZZLE TIP SHOULD BE ENCLOSED IN A
TRANSPARENT RECEPTACLE IF AVAILABLE.

ALL RIGHTS RESERVED
4. Bleed air from the nozzle.' Open the tester valve and operate tester handle for 8 to 10.
.. quick strokes to expel (bleed) air from the injector nozzle. Test fluid should spray from the
spray holes in the nozzle tip. If the nozzle is blocked or the needle jammed, replace the
injector. Replacement injectors should be. tested befo.re assembly to the engine.
NOTE: Conduct opening pressure, tip leakage a~d spray pattern tests separately. Do
not attempt to evaluate more than one test step or result at a time.
5. Check nozzle opening pressure by pumping the injector nozzle tester and observing .the
pressure at which the needle valve lifts and fuel is ejected from the nozzle tip. Opening
pressure must meet specifications or nozzle should be replaced.
6. Check the nozzle for tip leakage. Wipe the nozzle tip dry and operate the tester to
maintain pressure at 2068 kPa (300 psi) below opening pressure of the nozzle. Hold the
pressure for 10 seconds. If droplets form on the tip of the injector and fall off, the nozzle
should be replaced. Wetness on the tip of the injector is acceptable.
NOTE: Do not wipe' the tip with fingers, because it tends to draw a small amount of
fluid out of the injector giving a false impression of a Ieak. Use a. clean cloth
or blotting paper.
7. Check the spray pattern of the nozzle (Figure' 23) ~y pumping the tester handle rapidly
and observing the spray pattern coming from the orifices. Spray must come from each
orifice and be similar in size and consistency. The spray should be well atomized and
cone shaped as it comes from the injector nozzle. Injectors showing poor spray patterns
should be replaced.
ACCEPTABLE
UNACCEPTABLE
~ ..
UNIFORM & WELL
STRINGY NON-UNIFORM WITH ATOMIZED SPRAY
SPLIT STREAM SPRAY A9506-8
Figure 23 Spray Patterns

8. If the injector fails any of the tests, overhaul or replace the injector. Refer to Shop

ALL RIGHTS RESERVED
Checking Compression
To check compression in the 6.6l and 7.8l Ford Diesel engines use the following procedure:
1. Be sure battery performance meets specifications.
2. Clean the engine, especially the area around the injectors.
3. Warm up the engine by operating for a minimum of 30 minutes at 1200 rpm.
4. Stop the engine and remove the high-pressure fuel lines and fuel leak-off line from the
engine. Cap all the openings in the fuel injection system and fuel injection pump.
5. Remove the injector nozzle and seat washer from each cylinder. Cap the injector nozzle
and line to prevent the entry of dirt into the system. Place the injectors in a rack to
prevent damage while they are removed from the engine and to keep them in order.
i CAUTION i
If an injector is stuck in the cylinder head and will not pull straight out, turn the
injector in a clockwise direction to break it loose. If it is turned in a
counterclockwise direction there Is a chance that the nozzle and holder could
unscrew from each other, allowing the internal compe;>nents te;> fall out.
NOTE: The lines should not be capped until residual fuel has been removed from
them. Otherwise, when the engine is cranked during the compression test,
the fuel remaining in the lines will blow the caps off. To remove the residual
fuel, crank the engine after the fuel shutoff solenoid has been disconnected,
then cap the lines.
6. Disconnect the electrical connector at the bottom of the fuel shutoff solenoid (Figure 24)
and cover with tape. This must be done to shut off the flow of fuel to the engine during
cranking.
A9297-e
Figure 24 Fuel Shutoff Solenoid Terminals

7. Crank the engine to blowout any loose carbon particles from the injector bores.
8. Install the engine compression tester adapter 12210 into the injector bore of cylinder No.
1, using a new set washer and the injector mounting studs and nuts.
9. Connect Compression Gauge 014-00701 or equivalent and hose to the adapter.
10. Crank the engine (speed must be at least 200 rpm) and observe the gauge reading. Allow
about 6-8 puffs per cylinder.
11. Repeat Steps 7 through 10 for each cylinder.
12. After completing the compression check, install the injector nozzles using new seat
washers. Connect the injector lines back on the engine and attach the connector at the
bottom of the fuel shutoff solenoid.

ALL RIGHTS RESERVED
Checking Compression
Test Conclusions
1. Minimum compression must be at least 1896 kPa (275 psi). Also, compression readings
from the lowest cylinder must be at least 75 percent of the highest.
2. If any of the readings do not meet the above specifications, this indicates that there is
leakage at the cylinder head gasket, piston rings or valves.
NOTE: To determine if the rings or valves are at fault, squirt the equivalent of a
tablespoon of heavy 011 Into the combustion chamber, then crank the engine
to distribute the oil and repeat the compression test. The oil will temporarily
seal leakage past the rings. During a compression test, if the pressure fails
to climb steadily and remains the same during the first two succeeding
strokes, or fails to climb during the entire test, suspect a sticking valve.
3. A low, even compression in two adjacent cylinders may indicate a cylinder head gasket
leak. Check this before blaming the rings or valves.

ALL RIGHTS RESERVED
SECTION 20
Diesel Diagnosis - 7.3L Engine
Contents
Preliminary Checkout 20-1
Test Equipment 20-3
Idle Speed Setting Procedures 20-8
Setting Injection Timing - Static Timing 20-9
Setting Injection Timing - Dynamic Timing 20-10
System Description and Diagnosis 20-12
Glow Plug System Diagnostic Procedure 20-29
Engine Performance Diagnostic Procedure 20-47
Injection Nozzle Testing 20-57

ALL RIGHTS RESERVED
Diesel Diagnosis - 7.3L Engine 20-1
Preliminary Checkout
This Section covers adjustments, diagnostics, and test procedures for the 7.3L diesel engine
Fast Start Glow Plug System and Fuel Injection System.
Before Starting
Efficient diagnosis must take place in an organized manner with a plan or procedure which
starts with the obvious and goes on to the more difficult. Eliminate all the obvious and easy-
to-do items first. Do not start by jumping to conclusions. The job worked on last week might
have been caused by an entirely different problem than the one today.
Get All The Information Available
Check out all sources of information. Talk to the operator. Sometimes asking a question will
cause the operator to remember something that is useful.
The following list is a set of basic questions. Get the answers to these in order to learn what
the true complaint is, and what the basic problem is.
Operating Conditions:
1. Did the problem occur suddenly or over a long period of time?
2. Were there any abnormal noises before the failure?
3. Was the engine under heavy or light load? Decelerating or accelerating?
4. Did the water temperature or oil pressure vary?
5. Were weather conditions a factor?
6. What type of road grade was the vehicle on when the trouble was first noticed?
7. How was the trouble first noticed (felt, heard, etc.)?
8. What was the amount of oil consumption? Fuel? Coolant? Had there been a recent
change?
9. What was the exhaust smoke like? Lignt or dense? Color?
10. Does the engine have good throttle response?
11. Is deceleration normal?
12.' Does the engine shut off properly?
13. Does the ,engine start correctly when cold?
14. Does the engine ever miss?

15. What kind of fuel is being used? Grade and source?
16. Does the engine surge at idle or wide-open throttle?
17. Is the engine subjected to periods of extended idling?

18. Has the vehicle or equipment been in an accident or collision?

ALL RIGHTS RESERVED
202 Diesel Diagnosis -7.3L Engine
Preliminary Checkout
Maintenance History:
1. Has the engine been serviced recently? What was done?
2. Has this complaint occurred before? If so, what was done then?
3. When was the last tune-up?
4. When were the oil and fuel filters last changed?
5. Who normally performs the maintenance and adjustments?
6. Is the maintenance schedule followed closely?
7. How is fuel obtained and stored?
8. What type service designation (SG/CE), and what grade oil is used?
9. How many miles or hours has the engine operated since the last service?
Observed Information:
1. Is the engine clean or dirty?
2. Are the belts in good condition? Loose?
3. Is there evidence of external oil, coolant or fuel leaks?
4. Does the engine appear to have overheated?
5. Are there any make-shift repairs on the engine (loose parts, wired-on parts, etc.)?
6. How does the engine sound at idle?
7. Are any pulleys wobbling?
8. Do any parts appear to have been altered or serviced recently?
9. Are there any aftermarket or unapproved parts on the engine?
1O. Have any of the lines been altered or re-routed?
11. Are oil level, coolant level and fuel level satisfactory? (If the problem concerns bearings,
notice the condition of the oil.)
12. During disassembly, does the engine have unusual odors, carbon accumulations, dirt or
other conditions under the rocker cover?

ALL RIGHTS RESERVED
Diesel Diagnosis - 7.3L Engine 203
Test Equipment
The following test 'equipment (Figures 1 through 4) is required for adjusting idle speed and
timing.
A9983-8
BATTERY CONNECT CLAMPS
Figure 1 Rotunda 078-00200 Dynamic Timing Figure 2 T86T-9000-C Injection Pump

Meter Mounting Wrench
(]
A8917-8
A8549-8
Figure 3 Throttle Control Tool D83T-9000-E Figure 4 T83T-9000-C Injection Pump

Rotating Tool

ALL RIGHTS RESERVED
204 Diesel Diagnosis -7.3L Engine
Test Equipment
The following test equipment (Figures 5 and 6) is required for performing the 'Engine
Performance Diagnostic Procedure.
A8554-8
Figure 5 Rotunda 014-00761 Pressure Test

Kit
A8918-B
Figure 6 T83T-9000-A Fuel Transfer Pump

Pressure Adapter

ALL RIGHTS RESERVED
__T_e_s_t_E_q_U_i_p_m_e_n_t ~----------...J1
The following test equipment (Figures 7 and 8) is required for performing the "WAIT TO
START" Lamp Diagnostic Procedure and the Fast Start Glow Plug System Diagnostic .
Procedure.
A8S5S-S
Figure 7 12-Volt Test Lamp
Figure 8 Rotunda 007-00001 Digital Volt

Ohmmeter

ALL RIGHTS RESERVED
20-6 Diesel Diagnosis - 7.3L Engine
Test Equipment
The following test equipment (Figures 9 and 10) is required for Injection Nozzle testing and
cleaning.
A8557B
Figure 9 Rotunda 014-00300 Injector Nozzle

or equivalent Tester Special
Service Tool D83T-9000-F
E ~
,
6 is
( )
A8558-8
Figure 10 Rotunda 014-00301 Injector Nozzle

or equivalent Cleaning Kit Special
Service Tool D83T-9000-G

ALL RIGHTS RESERVED
I Test Equipment
ENGINE PERFORMANCE SPECIFICATIONS
Engine Model A-18S, A-166

Number of Cylinders 8
Configuration Vee
Bore 104.39 mm (4.11 in)
Stroke 106.20 mm (4.19 in)'
Displacement 7.3 Liters (444 cu in)
Crankshaft Rotation (viewed from
Counterclockwise
Flywheel End of Engine)
Compression Ratio 21.5:1
Firing Order '. 1-2-7-3-4-5-6-8
Idle Speed (No Load) * 650 rpm 50 rpm
Governor Speed (No Load) 3660 50 rpm
Governor Speed (Full Load Rated) 3300 rpm
Timing (Dynamic) 8.5 2 Degrees BTDC
Injection Pump .' Stanadyne DB-2
Injection Nozzle
Opening Pressure (New) 12,928 517 kPa (1875 75 psi)
Opening Pressure (Minimum) 9825 kPa (1425 psi)
Crankcase Pressure-No Load (Maximum) 20 kPa (6 in-H 20) @ 3300 rpm
Fuel Pressure (Filter Inlet) . 14 kPa (2 psi) @ idle
Fuel Pressure (Filter Outlet) 7 kPa (1 psi) @ 3300 rpm
Fuel Pump Suction 20' kPa (6 in. H20) @ 3300 rpm
Fuel Return Line Pressure 14 kPa (2 psi) @ 3300 rpm
Air Filter Restriction 107 kPa (25 in. H20) @ 3300 rpm
0
Valve Lifter
Valve Lash
Engine Lube Oil Pressure
69 kPa (10 psi)
Low Idle, Minimum
(Engine at Operating Temperature) 276-482 kPa (40-70 psi)
Crankcase Capacity (Without Filter) 8.5 L (9 qt.)
Crankcase Capacity (With Filter) 9.5 L (10 qt.)
Thermostat Opening Temperature 89C (19~OF) . ,
* Manual transmission in Neutral position. Automatic transmission in Drive position.

ALL RIGHTS RESERVED
208 Diesel Diagnosis - 7.3L Engine
Curb Idle Speed Adjustment

1. Place transmission in NEUTRAL or PARK.
2. Bring engine up to normal operating temperature.
3. Idle speed is measured with manual transmission in NEUTRAL and automatic transmission
in DRIVE.
4. Ensure. t""at curb idle adjusting screw is against the stop. If not, correct vehicle linkage.
5. Check curb idle speed, using Rotunda 055-00108 or equivalent. Curb idle speed is
specified on the Vehicle Emissions Control Information (VECI) decal. Adjust to specification
using idle speed adjusting screw (Fig. 11).
6. Place transmission in NEUTRAL or PARK. Rev engine momentarily. Place transmission in
specified gear and check curb idle rpm. Adjust again if necessary.
Figure 11 Idle Speed Adjusting Screw
Fast Idle Adjustment 00
At Cold Idle Solenoid:

1. Place transmission in NEUTRAL or PARK.
2. Start engine, and bring up to normal operating temperature.
3. Disconnect f.ast id!e solenoid from wiring harness.
4. Apply battery voltage to solenoid to activate it.
5. Rev engine momentarily to set solenoid to activate it.
6. Check fast idle speed setting. Fast idle rpm should be 825 25. Adjust to specification
by turning solenoid plunger in or out (Fig. 11).
7. Rev engine momentarily and check fast idle rpm. Adjust as necessary.
8. Remove battery voltage from solenoid connector and connect to wiring harness.

ALL RIGHTS RESERVED
Setting Injection Timing - Static Timing
1. Remove fast idle bracket and solenoid from injection pump.
2. Break torque (keeping nuts snug) on three nuts attaching injection pump to pump
mounting adapter using Tool T86T-90.00-C or equivalent (Figure 2).
3. Install rotating Tool T83T-9000-C (Fig. 4) or equivalent on front of pump and rotate
injection pump to align timing mark on injection pump mounting flange with timing mark on
pump .mounting adapter, to within 0.030 inch.
4. Remove rotating tool and tighten nuts to specification. Visually check timing to verify that
timing marks are aligned (Fig. 12)..
5. Install fast idle bracket and solenoid and tighten bolts to specification.
INJECTION PUMP
GEAR HOUSING
INJECTION
PUMP
INJECTION TIMING -
STATIC CHECK
A89200S
Figure 12' Injection Pump Timing Marks,

ALL RIGHTS RESERVED
Setting Injection Timing - Dynamic Timing
1. Bring engine up to normal operating temperature.

NOTE: When checking or setting dynamic injection timing on the 7.3L engine it is
mandatory that the engine be stabilized at normal operating temperature of 89C-
100C (192F-212F). This temperature is needed to ensure proper fuel ignition in the
precombustion chambers.
2. Stop engine and install Dynamic Timing Meter, Rotunda 078-00200 or equivalent, by
placing magnetic pickup in timing pointer probe hole (Fig. 13). Insert pickup until. it almost
touches vibration damper.
NOTE: To prevent incorrect readings, ensure that vibration damper is clean and free
of foreign debris and rust scale. If required, sand the area to remove rust and
apply a light coat of paint to the area.
3. Attach clamp from Timing Meter Adapter Rotunda 078-00201 or equivalent, to the line
pressure sensor on No. 1 injector nozzle (F-Series) or No. 4 injector nozzle (E-Series) and
connect to timing meter (Fig. 14).
IN-LINE
SENSOR
CLAMP
ROTUNDA
078-00201 A11464-A
Figure 13 Magnetic Pickup - Dynamic Timing Figure 14 Luminosity Probe - Dynamic

Timing
4. Connect dynamic timing meter to battery and dial in minus 20 degrees offset on meter.
Disconnect cold start advance solenoid connector from solenoid terminal (Fig. 11).
NOTE: Ensure that all wire leads are located away from the front accessory drive
belts.
5. With transmission in NEUTRAL and rear wheels raised off the ground, start engine. Using
Throttle Control Tool D83T-9000-E or equivalent, set engine speed to 2000 rpm with no
accessory load. Observe injection timing on dynamic timing meter. Injection timing should
be 8.5 degrees BTDC at 2000 rpm.
6. Apply battery voltage to cold start advance solenoid terminal to activate it.
NOTE: Activating cold start advance solenoid can result in engine speed increase.
Adjust throttle control to attain 2000 rpm, if required.
7. Check timing at 2000 rpm. The timing should be advanced at least 1 degree before the
timing obtained in Step 5. If the advance is less than 1 degree, replace fuel injection
pump top cover assembly.
8. If dynamic timing is not within 2 degrees of specification, adjustment of pump timing is
necessary.

ALL RIGHTS RESERVED
Setting Injection Timing - Dynamic'Timing
9. Turn engine off. Note timing mark alignment. Remove fast idle bracket and solenoid from
injection pump. Break torque (keeping nuts snug) on nuts attaching injection pump to
pump mounting adapter with Tool T86T-9000-C or equivalent (Figure 2).
10. Install rotating tool, T83T-9000-C or equivalent (Figure 4), on front of pump. Rotate
clockwise (when viewed from front of engine) to retard, and counterclockwise to advance
timing, by lightly tapping tool with a rubber mallet. Two degrees of dynamic timing is
approximately 0.75mm (.030 inch) of timing mark movement.
11. Remove rotating tool and tighten nuts to specification. Start engine and recheck timing.
Repeat Steps 9, 10 and 11 as necessary, to set timing to 1 degree of specification.
12. Turn engine off. Remove dynamic timing components. Install fast idle bracket and solenoid
and tighten bolts to specification.

ALL RIGHTS RESERVED
System Description
This portion of this Section contains a brief description of the 7.3L diesel engine "WAIT TO
START" Lamp System, Solid-State Glow Plug System and Fuel System. It also contains
detailed diagnostic procedures for these systems.
The diagnostic procedures are broken into two parts. The first part is Symptom Analysis. This
Section should be consulted first, as it will provide direction to perform a specific service or to
a specific diagnostic procedure.
The second part contains the "WAIT TO START" Lamp, Solid-State Glow Plug System,
Engine Performance diagnostic procedures, Fuel System Air Leak Diagnosis and Nozzle
Testing. At the beginning of each of these procedures, there is an explanation of how to use
that procedure. Read this explanation before performing the tests.

ALL RIGHTS RESERVED
Warning Lamps
"Wait To Start" Lamp
The "WAIT TO START" lamp comes on when the ignition switch is turned .to the RUN
position, and the engine is below normal operating temperature. It will remain lit for 4 to 10
seconds, depending on engine temperature. If engine is at or above normal operating
temperature the lamp will not turn on. '
NOTE: If the ignition switch Is left in the ON position for an extended period of time or
the engine is not started within the two minute cycling time, the glow plug
system must be reset by turning the ignition switch to OFF position.
Fuel Filter Restriction Warning Lamp
The 7.3L diesel is equipped with a fuel filter restriction sensor. A restriction indicator lamp is
located in the instrument cluster to alert the operator.
If the lamp comes on during normal engine operation, replace the tilter as soon as possible.
"Water In Fuel" Warning Lamp
The "WATER IN FUEL" warning lamp should turn on when the ignition switch is in the
START position to indicate proper lamp and sensor function. The lamp will come on if the fuel
filter/water separator has a significant amount of water in it. If the lamp comes on during
normal engine operation, drain the fuel bowl in the tilter as soon as possible. Water in the
fuel could cause extensive damage to the fuel injection system.

ALL RIGHTS RESERVED
Solid-State Glow Plug System
The Solid-State Glow Plug system consists of the glow plug controller, the glow plug harness
assembly and glow plugs (Fig. 15).
GLOW PLUG
CONTROLLER
ASSEMBLY
A9923-B
Figure 15 Solid State Glow Plug Control System
The system determines the glow plug temperature by electronically measuring the resistance of
the glow plugs. It then maintains this temperature regardless of ambient temperatures.
The system is actuated when the ignition switch is turned to the RUN position. The "WAIT
TO START' lamp lights until the glow plugs reach the proper temperature. The lamp goes out
I
and the engine can be started.
The afterglow operation of the glow plugs continues after the "WAIT TO START" lamp turns
off. The glow plugs cycle on and off for a period of time. This helps to reduce white smoke
after engine start-up.
The glow plug system can be recycled by turning the ignition off and on. This immediately
restarts the glow plug cycle. The engine can be started as soon as the "WAIT TO START"
lamp goes off.

ALL RIGHTS RESERVED
Diesel Diagnosis. - 7.3L Engine 2015
Glow Plug Controller
The power relay is mounted on top of the solid-state controller circuit board. The complete
assembly is mounted on the rear of the intake manifold (Fig. 16).
WAITTOSTART LAMP
CONNECTOR
CAUTION: DIRECT
CONNECTION TO
BAnERIES TEST
TERMINAL
A9924-B
Figure 16 Solid-State Glow Plug Controller
Glow Plugs
The system uses positive temperature coefficient (PTe) glow plugs. The resistance of the glow
plugs changes as the temperature rises. The glow plugs use bullet-type terminals (Fig. 17).
BULLET
TERMINAL
A9925-8
Figure 17 Glow Plugs

ALL RIGHTS RESERVED
Wiring Schematic
Use the electrical schematic (Fig. 18) when diagnosing the glow plug system.
FUSE LINK
(14GA.)(GR)---~ (16 GA) R/LG
~~SciA~;~;L) _ _-J~ -4 ) -;-., FUSE LINKS
0
IBATT BATTJ (20 GA.)
o
START (16 GA) RlLG
IGNITION ' ACCY 0 .. ~~ I ENGINE 16 GA.)
SWITCH LOCK O~F~~~ 1(20 GA.) CONNEC~OR OK BL
I
<i>
I ---- - ~R/LG ~ FUEL
I (10 GA) Y (2 WIRES) LINE
HEATER
1 --. FUSE (20 GA.)
6
LINKS BKlPK (20 GA)
o (14 GA.) BKlPK
----- STARTER ~
RELAY :z
C)
':" (0 GA) ~ (2 WIRES)

FUSE LINK
BATIERIES.I
LH I
r
'~I
+'
===I =
I -=-
I
RH
r
1~1
I I
I~I
+' rT-------l
II WAIT TO START
LAMP
I
I
I-=- L .J
~r ~I~
~ ~~~ ~~~~
LH GLOW PLUGS - RH GLOW PLUGS -
A9926-B
Figure 18 Wiring Schematic

ALL RIGHTS RESERVED
Diesel Diagnosi,s - 7.3L Engine 2017
Fuel System Description

I
Figure 19 shows a schematic of the' fuel supply and return lines. Fuel .from the tank is routed
to the fuel supply pump which pumps fuel through a combination fuel filter, heater and water
separator. The filter header contains a continuo,us vent (orifice bleed-off system) which aids
starting by eliminating the need to manually prime the fuel filter. A vacuum switch is
incorporated into the fuel filter header which will activate a light on the instrument panel
indicating the need for filter replacement. The water separator portion of the filter assembly
has a probe which will activate an instrument panel light when the filter requires draining at
the water' and sediment drain located on the bottom of the assembly.
Fuel enters the inlet of the injection pump and is delivered under high pressure through
injection nozzles into the engine cylinders for combustion. On each nozzle is a fuel return
fitting that returns excess fuel to the fuel tank. Excess fuel from the injection pump and each
injection nozzle are collected in bleed-off lines and returned to the fuel tank.
FUEL
SUPPLY
TANK
FUEL
RETURN
LINE FUEL
LIFT _ _ ~ ~ ~ / . 9 '
PUMP A9194-C
Figure 19 Fuel System Schematic
"

ALL RIGHTS RESERVED
20-18 Diesel Diagnosis -7.3L Engine
Symptom Analysis
Consult the Symptom Analysis Diagnostic Procedures first. These will indicate a service to be
performed or provide direction to either the Fast Start Glow Plug System Diagnostic Procedure
or the Engine Performance Diagnostic Procedure.
If the GLOW PLUG lamp is suspected' of being faulty, go directly to the GLOW PLUG
diagnostic procedure before performing the Glow Plug System Diagnostic Procedure.
If the problem is Loss of Power and/or Increased Fuel Consumption, go directly to the Engine
Evaluating "Normal" Diesel Engine Exhaust Smoke
The following is a description of what is "normal" and expected exhaust smoke ~or a vehicle
with a diesel engine. Diesel exhaust smoke can be classified into two categories according to
the color of the smoke.
The first category is blue-white smoke.
Blue-white smoke may be observed at engine start-up whether the engine is up to operating
temperatures or not. This start-up smoke will be observed at all ambient temperatures and
should last no longer than a minute after the vehicle is driven.
When ambient temperature is below 10C (50F), blue-white smoke can return after the
engine warm-up due to extended idling. This is due to the combustion chambers cooling
down during periods of extended idling time.
Heavy blue-white smoke will also occur when the engine is operated at wide-open throttle
(accelerator pedal to the floor) with the transmission in NEUTRAL or with a lightly loaded
vehicle in any transmission gear setting. The smoke is a normal characteristic for a diesel
engine with a light min.-max. governor spring in the fuel injection pump. This results in the
following characteristics due to the engine operating above its rated speed (3300 rpm) in a
no-load or lightly loaded condition:
Heavy blue-white smoke.
Fuel injection pump governor hunting resulting in high speed engine rpm surging.
Engine sputtering or misfiring.
The conditions can be eliminated by not operating the engine above its maximum full load
rated speed of 3300 rpm.
NOTE: Chassis fuel system air leaks may also cause continuous heavy blue-white
smoke.
The second category of diesel exhaust smoke is black smoke. Black smoke occurs whenever
the engine is working hard. The engine works hard when it is going up a steep grade, pulling
a trailer, carrying a heavy load, or during acceleration. More black smoke will be observed
when operating the vehicle at higher altitudes. If black smoke is observed while the engine is
idling (at low altitude) or under normal driving conditions, the problem should be diagnosed as
soon as possible.

ALL RIGHTS RESERVED
Diesel Diagnosis - 7.3L 'Engine 2019
I" Symptom Analysis
Engine Cranks But Will Not Start (Cold) :.............................. Pinpoint Test A
Engine Cranks ButWiII Not Start (Normal Opera.ting Temperature) . Pinpoint Test B
Engine Quits, Stalls or Stumbles :. '. .................... Pinpoint Test C
Engine Misses :..... ........................ ............................................. Pinpoint Test D
Engine Knocks : '. .............. Pinpoint Test E
Low Oil Pressure with Proper Oil Level .' ..... Pinpoint Test F
Blue/White Smoke (Engine at Normal Operating Temperature) Pinpoint Test G
Excessive Black Smoke ............. ........... ............. ..... ..... Pinpoint Test H
"Wait-To-Start;' Lamp Testing Pinpoint Test J
Glow Plug Testing .. ... ................ .............. .......... ..................................... Pinpoint Test K
Fuel System Air Leak Diagnosis " Pinpoint Test L
Low Power ;................... ....... Go to Engine Performance Diagnostic Procedure.
Increased Fuel Consumption .......................... Go to Engine Performance Diagnostic Procedure.

ALL RIGHTS RESERVED
Pinpoint
Engine Cranks But Will Not Start A
Test
AO I STARTING PROCEDURE
NOTE: If the ignition key is left in the ON

position for an extended period of time
@) ~ RETURN vehicle to
customer.
or the engine is not started within the
two minute cycling time, the glow plug
system must be reset by turning the f/iJ ~ GO to IA11.
ignition key to OFF position.
Check and follow correct starting procedure on
vehicle visor.
A1 I GLOW PLUG MODULE RELAY
Open hood. @) ~ GO to IA21.

Listen for glow plug module relay click when
ignition switch is turned to ON position. f/iJ ~ GO to Glow Plug
System Diagnostic
Procedure.
A2 I FUEL FLOW CHECK
Loosen one injection nozzle line nut (1/2 to one Fuel discharges ~ GO to Glow Plug
turn) while cranking engine. System Diagnostic
Procedure.
Fuel does not ~ GO to IA31.

discharge
A3 I ENERGIZE TO RUN SOLENOID (ETR)
Check voltage at ETR solenoid (terminal located

at front of injection pump) while cranking engine.
@) ~ GO to IA41.
Voltage must be at least 9 volts.

Check solenoid terminal for dirt/corrosion and
f/iJ ~ REFER to Shop
loose/broken electrical connection. REPEAT Test Step
IA31.
A4 1 CHECK COLD IDLE SPEED/ADVANCE
Check voltage at cold advance solenoid (terminal

located at left rear of injection pump) while
@) ~ GO to Engine
Performance Diagnostic
cranking engine. Voltage must be at least 9 volts. Procedure.
If no voltage is present, verify switching function
of temperature sensing switch located behind
thermostat housing.
f/iJ ~ REFER to Shop
REPEAT Test Step
IA41.

ALL RIGHTS RESERVED
Engine Cranks But Will Not Start Pinpoint

B
(Normal Operating Temperature) Test
80 I STARTING PROCEDURE
'Check and follow correct starting procedure on .@) ~ RETURN vehicle to

vehicle visor. customer.
~
~
~ GO to [II].
81 I FUEL FLOW CHECK
Loosen one injection nozzle line nut (1/2 to one Fuel. discharges ~ GO to Engine
turn) while cranking engine. Performance Diagnostic
Procedure.
Fuel does not ~ GO to 1821.

discharge
82 I ENERGIZE-TO-RUN SOLENOID (ETR)
With ignition switch in the ON position, check @) ~ GO to Engine

voltage at ETR solenoid (terminal at front of
injection pump). Voltage must be at least 9 volts. Procedure.
~
Check solenoid terminal for dirt/corrosion and
loose/broken electrical connection. ~ REFER to Shop
REPEAT Test Step
1821.

ALL RIGHTS RESERVED
Pinpoint
Engine Quits, Stalls or Stumbles
Test
c
CO I IDLE SPEED
TEST STEP RESULT
ACTION TO TAKE
Perform Test Step IEPC.10 I in the Engine

GO to IC11.
~ ADJUST idle speed as

described in this
Section, under
Adjustments.
C1 I ENERGIZE-TO-RUN SOLENOID (ETR)
Check ETR solenoid (terminal located at left front

of injection pump) for dirt/corrosion and loose/
~ GO to IC21 or IC31 as
required.
broken electrical connection. While cranking,
voltage must be at least 9 volts.
~ CLEAN, SERVICE or
REPLACE terminal
connection. REFER to
31-01. REPEAT Test
Step ~.
C2 I COLD ADVANCE SYSTEM (COLD ENGINE)
.
.Check voltage at cold advance solenoid (terminal
located at left rear of injection pump) while
cranking engine. Voltage must be at least 9 volts.
GO to Engine
Procedure.
~
If no voltage is present, verify switching function
of temperature sensing switch located behind REFER to Shop
thermostat housing.
REPEAT Test Step
IC21.
C3 I COLD ADVANCE SYSTEM (HOT ENGINE)
Check for voltage at cold advance solenoid

(terminal located at left rear of injection pump)
~ GO to Engine
while cranking engine. No voltage should be Procedure.
present.
~ ~ REPLACE temperature
sensing switch.
REPEAT Test Step
IC31.

ALL RIGHTS RESERVED
Diesel Diagnosis - 7:3L Engine 2023
Pinpoint
[Engine l\fisses D
Test
DO I DETERMINE WHEN MISS OCCURS
Engine will miss when cold if one or more glow

plugs are not heating.
Engine misses
only when cold
. REFER to Glow Plug
System Diagnostic
Procedure.
Engine misses ~ GO to 1011.

at normal
operating
temperature
01 I ISOLATE MISS
Loosen each injection nozzle line nut (one at a Miss not ~ GO to Engine
time) while running engine. Refer to Injection isolated to Performance Diagnostic
.
Nozzle Testing in this Section. specific cylinder Procedure.
Miss isolated to GO to 1021.

specific
cylinder(s)
02 I CHECK NOZZLE FUEL DELIVERY
Check injection nozzle fuel line(s) for kinks or Nozzle(s) and . GO to 1031 .
.
restrictions as described in Shop Manual, Section lines OK
22-08.
Perform injection nozzle test as described under Nozzle(s) and/ REPLACE damaged
Injection Nozzle Testing in this Section. or lines Not OK line(s) as described in
22-08. REPLACE
nozzle(s) as described
under Injection Nozzle
Testing in this Section.
03 I CYLINDER COMPRESSION CHECK
Perform cylinder compression test as described in

Shop Manual, Section 22-08.
@) ~ GO to Engine
Procedure.
~ ~ GO to 1041.
04 I CHECK CRANKCASE PRESSURE
Perform Engine Performance Diagnostic Procedure

Test Step EPC12.
@) ~ SERVICE or REPLACE
valve train as described
in Shop Manual,
Section 22-08.
~ ~ OVERHAUL power
cylinder as described in
22-08.

ALL RIGHTS RESERVED
20-24 Diesel Diagnosis -7.3L Engine
Pinpoint
IEngine Knocks Test
E
I BELT
EO DRIVEN ACCESSORIES
.
() GO to [ll].
~ .
Check engine front drive components for proper
operation.
SERVICE or REPLACE
as necessary. REFER
to specific accessory
Shop Manual Section.
I ENGINE
E1 COOLANT TEMPERATURE
.
()
~ .
Verify engine is not overheating. GO to IE21.
REFER to Shop
I ISOLATE
E2 ENGINE KNOCK
Loosen each injection nozzle line nut (one at a

time) while running engine. Refer to Injection
Engine knock .
not isolated to
GO to Engine
.
Nozzle Testing. specific cylinder Procedure.
f
Engine knock GO to IE31.

isolated to
specific
cylinder(s)
I CHECK
E3 NOZZLE FUEL DELIVERY
Check injection nozzle fuel line(s) for kinks or

restrictions as described in Shop Manual Section
22-08.
Nozzle(s) and
lines OK
. GO to Engine
Procedure.
Perform injection nozzle test as described under

Injection Nozzle Testing.
Nozzle(s) and/ ~ REPLACE damaged
or lines not OK line(s) as described in
22-08. REPLACE
nozzle(s) as described
under Injection Nozzle
Testing.

ALL RIGHTS RESERVED
Pinpoint.
Low Oil Pressure With Proper Oil F
Test
FO lOlL PRESSURE TRANSDUCER
Verify accuracy of oil pressure transducer. Use @). ~ GO to [TI] .

Adapter 5633 with Pressure Test Kit 014-00761 or
equivalent. Refer to Pressure Test Kit hookup'
illustration in this Section. ~ ~ REPLACE transducer.
REPEAT Test Step
IFOI.
I
F1 I CHANGE ENGINE OIL AND FILTER
Change engine oil and filter and run engine until @) ~ RETURN vehicle to
customer.
normal operating temperature is reached. Check
oil pressure reading.
. ~ ~ SERVICE or REPLACE
lubrication system
components as
necessary. (REFER to
22-08.)

ALL RIGHTS RESERVED
Blue/White Smoke (Engine At Pinpoint

G
Normal Operating Temperature) Test
GO I ENGINE TEMPERATURE
NOTE: Refer to Symptom Analysis. @) ~ GO to IG21.

Verify that engine stabilizes in normal operating
range. r$J ~ GO to !G11.
G1 I THERMOSTAT OPERATION
Remove thermostat. (Refer to Shop Manual, @) ~ REPLACE thermostat

housing with integral air
Section 22-08.)
bleed check valve.
Test thermostat for proper operation. (Refer to REPEAT Test Step
Shop Manual, Section 22-08.) IGOI.
r$J ~ REPLACE thermostat.

(REFER to Shop
Manual, Section 22-08).
REPEAT Test Step
IGOI.
G2 I EXCESSIVE OIL LEVEL
Check engine oil level indicator for excessive oil @) ~ GO to IG31.

fill.
r$J ~ DRAIN excess oil from

oil pan. If problem still
exists, GO to IG31 .
G3 I FUEL RETURN
Perform fuel return pressure test as described in @) ~ PERFORM entire

Engine Performance
Test Step EPC5 of the Engine Performance
Diagnostic Procedure. Diagnostic Procedure.
r$J ~ SERVICE or REPLACE

fuel return line(s) as
necessary. (Refer to
24-50.) REPEAT Step
IG31.

ALL RIGHTS RESERVED
Pinpoint
H

~
HO I VERIFY SMOKE LEVEL
NOTE: Refer to Symptom Analysis Light load and/ ~ GO to IH11.

or low altitude
Verify under what conditions black smoke occurs. NOTE: For warranty
claim approval,
Engine Performance
.. Chart must be filled
out for the following
steps: IEPC.21 ;
IEPC.61 ; IEPC.11I ;
IEPC.131.
Under heavy ~ Normal when going up

load steep grades, pulling a
trailer, maximum load,
maximum acceleration
or at high altitudes.
H1 I EXHAUST SYSTEM CONDITION
Complete Test Step EPC2 of Engine Performance @) ~ GO to IH21.

Diagnostic Procedure, and record problem
description and results on Engine Performance
Chart. ~ ~ SERVICE or REPLACE
exhaust system as
necessary. (REFER to
26-01.) If problem still
exists, GO to H2.
H2 I CHECK AIR CLEANER RESTRICTION
Complete Test Step EPC6 of Engine Performance @) ~ GO to IH31.

Diagnostic Procedure and record results on Engine
Performance Chart.
~ ~ REPLACE air filter
element and/or
SERVICE system.
REPEAT Test Step
IH21 .

ALL RIGHTS RESERVED
Pinpoint
H
H3 I INJECTION PUMP TIMING
Complete Test Step EPC10 of Engine @) ~ GO to IH41 .

Performance Diagnostic Procedure and record
re'sults on Engine Performance Chart.
0 ~ ADJUST timing.
(REFER to Adjustments
in this Section.) If
problem still exists, GO
to IH41.
H4 I INJECTION NOZZLES
Complete Test Step EPC11 of Engine @) ~ REPLACE injection

pump as described in
Performance Diagnostic Procedure and record
result~ on Engine Performance Chart. Shop Manual, Section
22-08,
0 ~ REPLACE damaged
injection nozzle fuel
inlet lines (REFER to
22-08). REPLACE
nozzles as described in
this Section, and Shop
If problem still exists,
REPLACE injection
pump as described in
22-08.

ALL RIGHTS RESERVED
Diesel Dlagnosis.-.7.3l Engine 20-29
Solid-State Glow Plug Sy~tem

Diagnostic Procedure
Perform the Glow Plug System Basic Diagnostic Test (hereafter referred to as Basic Test) first.
If the vehicle passes the Basic Test without running any Pinpoint Tests, the Glow Plug system
is OK and the vehicle's problem exists somewhere else other than the Glow Plug System.
However, if a step of the Basic Test fails, run only the Pinpoint Test specified by the failed
step.
Refer to Figure 20 for test lamp connections and Glow Plug System wiring harness test points
referred to in the Basic Test and the Pinpoint Tests. Perform only those services specified by
the Pinpoint Tests.
Operation of the Glow Plug System is completely automatic. If, after completing a specific
Pinpoint Test it is determined that a component must be replaced, the glow plugs should be
disconnected until system has been re-checked by repeating the Basic Test to make sure the
Glow Plug System works properly.
A Fast Start Glow Plug System Troubleshooting Chart is available for use by technicians. The
technician can use it as a check list while performing tests and diagnostic procedures.
CONNECTOR FROM ENGINE COOLANT ~ OIL PRESSURE .

IGNITION GROUND
TEMPERA~URE~~~i:
A
TO WAIT
(TRIGGER) STUD SENDER
LAMP SENDER COOLANT TEMPERATURE
IGNITION SWITCH
SWITCH FUEL
FROM "WAIT TO ~ ~ HEATER
BATIERY START" LAMP BATTERY
BATIERY FEED
FEED ELECTRICAL CONNECTOR, GLOW PLUG HARNESS TO
CHASSIS HARNESS CHASSIS SIDE VIEW
TERMINAL WIRE COLOR CODES
IGNITION SWITCH RED W/LIGHT GREEN STRIPE
TO GLOW "WAIT TO START" LAMP BLACK W/PINK STRIPE
PLUGS BATIERY FEED YELLOW
WIRE COLOR CODES
BATIERY FEED YELLOW
TERMINAL COLOR
OIL PRESSURE SENDER WHITE WIRED STRIPE
TRIGGER OK. BLUE
COOLANT TEMPERATURE SENDER RED WIWHITE STRIPE
GROUND REOIWHITE
COOLANT TEMPERATURE SWITCH RED W/BLACK STRIPE
BATIERY YELLOW
IGNITION LEAD TO
GLOW (LH) ORANGEIWHITE FUEL HEATER DARK BLUE
PLUGS (RH) BROWN
WAIT LAMP BLACK/PINK A98820C
Figure 20 Glow Plug System Diagnostic Test Points .

ALL RIGHTS RESERVED
Glow Plug Pinpoint Testing
The following is a series of Pinpoint Tests that can be used to diagnose the glow plug
system.
; CAUTION i
Never bypass the timed pulse function of the glow plug system. A constant 12 volt
current to the glow plugs will cause them to overheat and fail within seconds, possibly
resulting in severe engine damage.

ALL RIGHTS RESERVED
"Wait-To-Start", Lamp
Pinpoint J
Testing
J1 "WAIT-TO-START" LAMP STAYS ON
Disconnect the "wait-to-start" lamp connector at Lamp On ~ SERVICE wiring to

control unit. lamp.
Turn ignition switch to ON position.

Lamp Off ~ DISCONNECT power at
both batteries.
WAITTo-START
LAMP CONNECTOR REPLACE control unit.
A9978-S
J2 "WAIT-TO-START" LAMP DOES NOT

GO ON
Disconnect the "wait-to-start" lamp connector at Lamp On ~ GO to Hard Starting

control unit. Checks.
Connect jumper wire from harness side to ground.

Lamp Off ~ REPLACE bulb or
Turn ignition switch to ON position. SERVICE wiring.
CONTROL UNIT SIDE
~
HARNESS SIDE
A9979-B

ALL RIGHTS RESERVED
Pinpoint
IGlow Plug Testing Test
K
K1 CHECK GLOW PLUGS
Ignition switch in OFF position and leads removed GO to IK21.

from glow plugs.
Check continuity between glow plug terminal and REPLACE plug(s). GO
a power source with glow plugs installed in to IK21.
engine.
A997o-B

ALL RIGHTS RESERVED
. Diesel Diagnosis - 7.3L Engine 2033
Pinpoint
K
K2 CHECK HARNESS
Ignition switch in OFF position and leads removed OK at all leads GO to IK31.
from glow plugs.
Squeeze sides of protective cover and remove. Not OK at any SERVICE or REPLACE
or all leads harness. GO to IK31 .
Check continuity between each glow plug lead
and test terminal of control unit.
PROTECTIVE SQUEEZE SIDES
COVER AND LIFT
..
REAR OF
ENGINE
SQUEEZE SIDES
AND LIFT
A9971-8
TEST TERMINAL
A9972B
K3 CHECK CONTROL UNIT
Ignition switch in OFF position. Less than GO to IK41.

ohm
Contact ohmmeter to ground wire terminal eyelet
and to ground post on each battery.
More than 1 CLEAN or SERVICE
ohm ground connection.
REPEAT check. GO to
IK41.
A9973-B

ALL RIGHTS RESERVED
20-34 Diesel Diagnosis - 7.3L Engine .
Pinpoint
K
K4 CHECK SUPPLY VOLTAGE
Ignition switch in OFF position. More than 10 ~ GO to IKSI.

volts
Connect voltmeter to control unit power terminal
and ground.
Less than 10 ~ SERVICE wiring or
volts RECHARGE battery.
GO to IKSI. .
POWER ---,,~H()
TERMINAL
CAUTION: DIRECT ~~""'--_ _,..j

CONNECTION TO
BATTERIES
A9974-B
K5 CHECK VOLTAGE FROM IGNITION SWITCH
Check voltmeter to Ignition Terminal on control More than 8 ~ GO to IK61.

unit and ground. volts
Turn ignition switch to ON position and all

accessories off. Less than 8 ~ CHECK fusible link,
volts SERVICE wiring or
IGNITION TERMINAL RECHARGE battery.
GO to IK61.
A1975-B

ALL RIGHTS RESERVED
Diesel Diagnosis -7.3L Engine 20-35
Pinpoint
K
K6 I FUNCTIONAL TEST
With ignition switch in OFF position connect 12 Test light times ~ System function is
volt test light to test terminal on control unit. within correct.
Position test light so it can be viewed from specifications
driver's position.
Turn ignition switch to ON positionand monitor Test light times ~ DISCONNECT power at
system operation. out of both batteries.
Compare test light times to Test Light Chart. specifications REPLACE control unit.
REPEAT test.
~ -
11
A9976-8
TEST LIGHT CHART

NOTE: Total Test Light "ON" Time includes time
from the beginning of the initial "ON"
cycle" to the end of the last "ON-OFF
cycle" measured in seconds.
Control* "Wait-to-Start" Test
Unit . Lamp Light
Temp. "ON" Total
of Time (Sec.) Time (Sec.)
-20C 7-15 35-70
OF 7-12 25-60
35F 5-12 15-35
140F 1 or Less 1-3

* Temperature of Control Unit, NOT ambient
temperature
NOTE: The "Wait-to-Start l l Lamp and/or Test

Light may not illuminate if engine
temperature is at or near normal

ALL RIGHTS RESERVED
Glow Plug Failure Analysis
The following are examples of Glow Plug Failure. Each example gives a different clue to glow
plug failure analysis.
There is no visible damage, but glow plug is electrically open (Fig. 21). This indicates an
internal heating element failure. .
Glow plug tip that is missing can be caused by incorrect timing or poor fuel quality (Fig. 22).
Multiple, distorted glow plugs are usually caused by electrical overheating (Fig. 23). A
complete evaluation of the glow plug control system should be made.
TIP INTACT
TEST LIGHT WILL NOT

ILLUMINATE
A9981-8
A9980-8
Figure 21 Electrically Open Figure 22 Missing Tips
~-e..- -"DISTORTED" TIP
A9982-8
Figure 23 Distorted Tips

ALL RIGHTS RESERVED
Diesel Diagnosis '- 7.3L Engine 2037
Fuel System Air Leak Diagnosis
Hard starting, white smoke in the normal engine operating range, poor idle quality, or lack of
power under load can be caused by several conditions. One of these conditions is air leaks in
the fuel supply system. This procedure is provided to assist in the diagnosis of 7.3L diesel
engine fuel system ~ir leaks.
To perform the Fuel System Air Leak Diagnosis, the following adapters (Fig. 24 and 25) need
to be assembled as shown from locally available materials.
INSTALL THIS END INTO INLET INSTALL THIS END INTO

AND OUTLET HOSES AT WATER! INLET AND OUTLET FmlNGS
FUEL SEPARATOR OR FUELJlNATER SEPARATOR
~,..._...,~-----_r.,...-~
,...-----------.-./
--- --- --- - -....
TRANSPARENT POLYVINYL CHLORIDE

(TYGON~ ) HOSE-318 INCH 1.0.
INSTALL AND TIGHTEN HOSE 254MM (10 INCHES) LONG
CLAMPS TO 1-1.5 N'm (8-13 LB-IN)
....- - - - - - - - - - 2 . 5 0 INCH-------------~
..... _ . BOTH ENDS

1.0 INCH
0.43 INCH
01A.
0.028-.035 INCH WALL THICKNESS
PLASTIC, STEEL, OR BRASS FmlNG
VIEW A
......- - - - - - - - 3 / 8 INCH 0.0.
A9254-8
Figure 24 Water/Fuel Separator Adapter, Two Required
INSTALL AND TIGHTEN

HOSE CLAMPS TO 1-1.5 N'm (8-13 LB-IN)
STRAIGHT CONNECTOR (SHOWN) CONNECTOR

N803572S190 N803977S190
WALL THICKNESS:
0.a5-1.15MM
90 DEGREE CONNECTOR (0.034-0.046 INCH)
N8036OO-S190
A9261-8
Figure 25 Selector Valve/Fuel Tank Push Connect Adapter - F-Series (Two Required)

ALL RIGHTS RESERVED
Pinpoint
Fuel System Air Leak Diagnosis L
Test
L1 CHECK HOSE CONNECTIONS
NOTE: Prior to starting the diagnostic procedure, ~ GO to IL21 .

verify that the fuel tank(s) contain at
least a half tank of fuel - the fuel level
compensates for the range of vehicle
f/j~ SERVICE or REPLACE
fuel lines, clamps or
attitudes that may uncover the fuel push-connect fittings.
sender pickup hose or sender by-pass in REFER to Light Truck
the fuel tank when the fuel level is low. Shop Manual, Volume
Visually inspect the fuel system for B, Section 25-50, for
obvious problems such as kinked hoses, push-connect fitting
damaged lines or push-connect fittings. service.
Verify that the push-connect fitting clip is in place.

Verify that the push-connect fittings are properly
installed on the tube end by pulling the fitting
away from the tube (axially along the tube). The
fitting should not pull off from the tube end. If the
fitting does pull away, push the fitting axially back
on to the tube until a definite click is heard.
Pull and push the fitting one more time to verify
proper installation.
A11546-A

ALL RIGHTS RESERVED
Diesel Diagnosis - 7.3L Engi,ne 2039
Pinpoint
Test
L2 I CHECK SYSTEM FOR BUBBLES OR FOAM
Remove the rubber fuel return bypass hose which @) ~ Problem elsewhere in
system. REMOVE
connects the fuel filter outlet fitting bypass orifice
to the return lines at the fuel i,njection nozzles. TYGON hose and
INSTALL original hose.
; CAUTION 1 REFER to Symptom
Analysis in this Section.
Care should be taken when removing or
installing hose to the plastic fitting at the fuel
Injection nozzle return lines. Lubricate hose with
diesel fuel to ease installation.
~ ~ GO to IL31.
Install a 305mm (12-inch) length of 3/16" 1.0.

clear polyvinyl chloride, TYGON hose (to "
view fuel flow) in place of the above rubber fuel

hose, then tighten hose clamps to 1-1.5 Nom (8-
13 Ib-in).
Run engine at approximately 3,000 rpm for two to
three minutes to clear air from the system, which
was induced by the previous operation.
Observe fuel hose for air bubbles at 3,000 engine
rpm.
Any continuous stream of bubbles larger than
1.58mm (1/16 inch) indicates air ingestion. A
moving concentration of bubbles of any size, or
foam, is unacceptable.
NOTE: TYGON is a registered trademark of ~
Norton Industries Plastics.

ALL RIGHTS RESERVED
Pinpoint
Test
CHECK SYSTEM FOR BUBBLES OR FOAM

L2
(Continued)
FUEL RETURN
FILTER HEADER MOUNTING
HARDWARE: HOSE (LEAK-OFF)
ELBOW
(2) 3/8-16 x 1-3/8" BOLTS 3/8-16 x 3-1/2"
(4) HARDENED WASERS FLANGE HEAD
(2) HEX NUTS
BOLT
FUEL RETURN <t ENGINE

HOSE (IN
PHANlOM)
FILTER 10
INJECTION _..>0...-"
PUMP TUBE
CONNECTOR
NUT
3/816 x 11/4"
CONNECTO~
~I=====i-FLANGE HEAD
BOLT
FITTING
ALTERNATOR
WATER BRACKET
DRAIN WATER
TUBE
CLAMP
DRAIN --f---ct
(2 PLACES) TUBE INVERTED CRANKSHAFT
FLARE
TUBE NUT
RIGHT SIDE VIEW F-SERIES FRONT VIEW A12724-A

ALL RIGHTS RESERVED
Pinpoint
Test
CHECK SYSTEM FOR BUBBLES OR FOAM

L2
(Continued)
ELBOW FUEL FILTER!

FUEL RETURN
FILTER TO WATER SEPARATOR
HOSE
INJECTION ASSEMBLY
(LEAK-QFF)
PUMP TUBE
WATER
DRAIN
,TUBE
~
,
I
<t ENGINE
WATER
CRANKSHAFT --------- PUMP
,HOUSING
INVERTED
RIGHT SIDE VIEW FLARE TUBE ;NUT E-SERIES FRONT VIEW A12725-A

ALL RIGHTS RESERVED
2042 Diesel Diagnosis - 7.3L .Engine
Pinpoint
Fuel System Air Leak Diagnosis .L
Test
L3 I CHECK DIRECTION OF FLOW
Observe direction of flow of bubbles. Bubbles

should flow from fuel filter outlet fitting to the fuel
~ GO to IL41 for single
tank system.
injection nozzle return system.
GO to ILsi for dual
tank system.
~ ~ Fuel System is
restricted. GO to
Engine Performance
Diagnosis in this
Section. PERFORM
Steps I EPC4A I through
IEPC4DI.
L4 I CHECK HOSE CONNECTIONS
Check tor damage to hose connections at rubber

fuel hose from chassis fuel line to mechanical lift
~ REPLACE TYGON
hose with original hose.
pump and at inlet and outlet hoses at water" Problem resolved.
separator.
Tighten hose clamps to 1-1.5 N-m (8-13 Ib-in). ~ ~ GO to ILSI.
After tightening hose clamps. run engine for five

minutes at 3,000 rpm and check for air bubbles in
TYGON hose.

ALL RIGHTS RESERVED
DieseIDiagnosls.~ 7.3L Engine 2043
Pinpoint
Fuel System Ai~' Leak Diagnosis L
Test"
L5 ICHECK FUEL FILTER/WATERSEPARATOR

FOR BUBBLES
.,
Disconnect fuel filter/water' separator inlet hose: Air' bubbles ~ SERVICE hoses' and
Install hose adapter and tighten clamps to 1-1.5 present in inlet connections between
N-m (8-13 Ib-in). hose, single fuel/water separator as
tank system. necessary. REPEAT
NOTE: Refer to Air Leak Diagnosis - Hose Test Step ILsi.
A~apter procee:tures in this Section.
Disconnect fuel/water 'separator outlet' hose'.. Install Air bubbles '~ GO to IL61.
hose adapter and tighten clamps to .1 ~ 1:5 'Nm. (8- present in inlet
13 Ib-in). hose, dual tank
system
i CAUTION I
Disconnect hoses and install adapters one at a ' Air bubbles ~ CHECK hose adapter
time to prevent hose mix-up.' present in at fuel/water separator
.. - outlet hose inlet for air,1eaks.
Operate engine at 1,500 rpm' for five minutes "to only Operate water/fuel
develop steady fuel flow. Then, operate engine at separator drain with
3,000 rpm for an additional two' minutes and engine' off. REPEAT
check for bubbles in hose a.dapter~. ' Test Step I LsI: .
If bubbles persist,
.' REPLACE water/fuel
, . separator. REPEAT
Test Step IL21.
"

ALL RIGHTS RESERVED
Pinpoint
Test
CHECK FUEL FILTER/WATER SEPARATOR

L5
FOR BUBBLES (Continued)
FUEL RETURN
FILTER HEADER MOUNTING
HOSE (LEAK-OFF)
ELBOW HARDWARE:
(2) 3/8-16 x 1-3/8" BOLTS
(4) HARDENED WASERS
(2) HEX NUTS
FUEL RETURN
HOSE (IN
PHANlOM)
FILTER 10
INJECTION
PUMP TUBE
CONNECTOR
NUT
3/8-16 X 1-114"
CONNECTO~
~I:=====;-FLANGE HEAD
BOLT
FIITING
ALTERNATOR
WATER BRACKET
DRAIN WATER
TUBE DRAIN -~--ct
CLAMP
(2 PLACES) TUBE CRANKSHAFT
RIGHT SIDE VIEW FRONT VIEW A12724-A

ALL RIGHTS RESERVED
Diesel Diagnosis -7.3L Engine 2045
Pinpoint
Test
CHECK FUEL FILTER/WATER SEPARATOR

L5
FOR BUBBLES (Continued) .
ELBOW FUEL FILTER/

FUELAETURN WATER SEPARATOR
FILTEATO HOSE
INJECTION ASSEMBLY
(LEAK-OFF)
PUMP TUBE
WATER
DRAIN
TUBE
. It 'ENGINE
fC 1 WATER
CRANKSHAFT PUMP
HOUSING
INVERTED
RIGHT SIDE VIEW FLARE TUBE NUT ESERIes FRONT VIEW . A12725A

ALL RIGHTS RESERVED
Pinpoint
Test
L6 OPERATE SELECTOR VALVE - DUAL TANKS
Start and run engine. Bubbles present ~ GO to IL41 .

Observe TYGON@ hose while switching selector in both tank
valve between tanks. positions
Bubbles present ~ GO to IL71 .

in only one
tank position
L7 CHECK SELECTOR VALVE CONNECTIONS
Check push-connect f\ttinys for tightness as ~ GO to ILsl.

outlined in Test Step L1 .
Fittings should be tight. ~ SERVICE push-connect
fittings, as necessary.
REFER to Shop
for push-connect fitting
service.
L8 BY-PASS SELECTOR VALVE
Disconnect push-connect fittings from fuel tank Bubbles not ~ Air leak is between
selector valve for affected tank. present in fuel tank selector valve
Install push-connect fitting adapters between fuel either adapter and water/fuel
lines and selector valve. separator. SERVICE
fuel lines and
Run engine at 3,000 rpm for two to three minutes connections as
to clear any air ingested during adapter necessary. REPEAT
installation. Run engine an additional one to two Test Step IL21.
minutes and observe transparent fuel lines in
adapters.
Bubbles present ~ Air leak is between
in both fuel tank and selector
adapters valve. SERVICE fuel
MIDSHIP TANK
RETURN lines and connections
MIDSHIP TANK as necessa~REPEAT
SUPPLY Test Step l..J4.I .

Bubbles present REPLACE fuel tank
in selector selector valve. REPEAT
valve outlet Test Step IL21 .
adapter only.
AFT AXLE
TANK --~
RETURN

AFT AXLE
TANK SUPPLY
1. INSTALL ONE ADAPTER AT POINT A

2. INSTALL OTHER ADAPTER AT:
POINT 8 FOR MIDSHIP TANK
POINT C FOR AFT AXLE TANK .1154

ALL RIGHTS RESERVED
Engine Performance Diagnostic Procedure
The Engine Performance Diagnostic Procedure begins with those items which are the high'
frequency, easy-to-diagnose problems, and progresses to the low frequency, hard to diagnose
problems. Use of this procedure will promote rapid as .well as accurate diagnosis.
The Engine Performance Diagnostic Procedure follows, step by step, tt:le Engine Performance
Chart. Each test step is labeled to coincide with the Engine Performance Chart steps.
NOTE: Under no circumstances should the fuel injection pump be replaced until the
Engine Performance Chart has been completely filled out. The only exceptions to
this is in the case of Excessive Black Smoke (Symptom Analysis Diagnostic
Procedure H) and external leaks. In these cases, only those steps specified need
to be filled out. Warranty claims for the fuel injection pump or injectors will not
be accepted unless the Engine Performance Chart is filled out as specified and
all tamperproof seals are intact.
NOTE: Service each problem detected before going on to the next step. If service
corrects the original complaint, it will not be necessary to proceed to the next
test step. However, if the complaint is not corrected, continue with the test until
the complaint is corrected.
The following explanations refer to the basic test steps of the Engine Performance Diagnostic
Procedure and Chart. They give a brief description of how these problems can affect
. performance, and an understanding of the importance of each test step.
1. External Leakage: Fuel leakage can be a reason for diesel fuel smell or low economy. Oil
leakage can be a reason for high oil consumption. An air intake system leak can shorten
engine life, especially under dusty conditions. Coolant leakage can result in engine
overheating.
2. Exhaust System Condition: Kinks or dents in the exhaust system can cause high exhaust
back pressure. This can result in loss of power and high smoke levels.
3. Fuel Quality: Diesel engines need clean fuel, free of air, dirt and water. Any contamination
may result in poor engine performance.
4. Fuel System Condition: Kinks in the fuel lines or hoses can block or restrict fuel flow and
loose connections can leak air into the fuel. This can result in loss of power and high
smoke levels.
NOTE: The fuel supply system must deliver the proper quantity of fuel with no
pressure loss or air leaks in chassis fuel system.
5. Fuel System Return Line Restriction: A restriction in the fuel return line will raise the
pressure in the injection pump causing an adverse effect on injection pump timing,
resulting in excessive smoke levels or loss of power.
6. Air Cleaner Restriction: A dirty air cleaner may result in low power, excessive smoke and
poor fuel economy.
7. Transfer Pump Pressure: This is the pressure which is available to charge the injection
plunger. Low pressure will result in low power, and excessive smoke levels.
8. Accelerator' Linkage: If the accelerator linkage is improperly adjusted, the engine cannot
reach full rated rpm and top speed and pulling power will be reduced, or curb idle speed
will be excessive.

ALL RIGHTS RESERVED
9. Engine Idle Speed: Low engine idle speed may cause stalling or rough running.
10. Injection Timing: Incorrect timing can be responsible for poor fuel economy, rough idling or
hard starting and excessive smoke.
11. Injection Nozzle Test: The injection nozzles must be removed from the engine for this
test. This is a functional test of injection nozzle performance. Incorrect nozzle performance
will cause misses, poor fuel economy, loss of power and excessive smoke.
12. Crankcase Pressure: This test measures the amount of crankcase blow-by. More blow-by
will create high pressures. Crankcase pressure readings, plus rate of oil consumption,
should be used to evaluate engine mechanical condition.
To perform the Engine Performance Diagnostic Procedure it will be necessary to connect the
Pressure Test Kit, Rotunda 014-00761 or equivalent, to the various components as shown in
Figure 26.
NOTE: If the problem is hard starting, follow the procedures for troubleshooting the
glow plug system prior to troubleshooting the fuel system.

ALL RIGHTS RESERVED
Diesel Diagnosis -7.3L Engine 2049
TO GAUGE
WITH
RANGE
REQ'O
FOR LEAK
TEST
NOTE:
DO NOT CONNECT 80TH PORTS OF THE
IIAGNEHELIC GAUGE AT ONCE. WHEN
TAKING A READING (VACUUM OR FUEL RETURN
RESTRICTION AT SUPPLY PRESSURE) lEAVE THE OTHER PORT LINE PRESSURE
PUIIP INLET OPEN TO ATMOSPHERE. TESTS
TEST 40
A11466-C
Figure '26 Pressure Test Kit Hookup - Rotunda Model 014-00761

ALL RIGHTS RESERVED
Pinpoint
Test
EPC1 \ CHECK FOR EXTERNAL LEAKAGE
With engine running, visually check for leakage of: No leakage ~ GO to IEPC21.
1. Fuel
2. Engine oil Leakage ~ SERVICE or REPLACE
3. Proper installation and dirt past air cleaner detected faulty component(s). If
problem still exists, GO
4. Coolant to IEPC21.
I
EPC2\ CHECK EXHAUST SYSTEM
Visually check exhaust system for dents or kinks

which could cause restriction. ~ GO to \EPC3AI.
fB ~ SERVICE or REPLACE
exhaust system as
required. (Refer to
26-01,) GO to .
IEPC3AI.
EPC3A \ CHECK FOR AIR IN FUEL
Install a length of clear PVC hose in place of Fuel flow ~ GO to IEPC3SI.

rubber hose between fuel filter outlet and injection direction OK,
nozzle return system. bubbles less
Run engine for two minutes. Then, run engine at than 1.58mm
3,000 rpm and check for bubbles in clear hose. (1/16 inch)
diameter.
NOTE: Correct direction of fuel flow is from fuel
filter toward fuel return system. Fuel flow
in opposite direction is indication of Fuel flow ~ GO to Fuel System Air
restriction in fuel supply system. direction OK, Leak Diagnosis in this
bubbles Section. REPEAT Test
NOTE: On vehicles with dual fuel tanks, check 1.58mm (1/16 Step IEPC3A I when air
with tank selector switch in each position inch) diameter leaks are eliminated.
for a minimum of two minutes. or larger
Fuel flow ~ GO to IEPC5A/.

direction not
OK REPEAT IEPC3A I,
when fuel flow direction
is corrected.
EPC3B\ CHECK FUEL FOR CONTAMINATION
Obtain a fuel sample and visually examine fuel in

a clear container (including bottom of container), ~ Go to IEPC3CI.
for particles, clouding, or liquid contamination,
such as water. fB ~ REPLACE fuel filter.
CLEAN and/or
SERVICE fuel system
as required. Refer to
24-50.
GO to !EPC3CI.

ALL RIGHTS RESERVED
Pinpoint
Test'
EPC3CI CHECK FUEL FOR CETANE VALUE
Check cetane value of fuel sample taken in Test More than 40 ~ GO to EPC4A.
Step EPC3B using cetane tester included with
Dynamic Timing Meter, 078-00200 or equivalent. Less than 40 ~ Complete Tests E~C4,
Cetane value should be minimum of 40. 5, 6 and 8.
INFORM owner to
change fuel source.
GO to IEPC4AI.
*NOTE: Do not
replace fuel
injection
pump
because of
low cetane
problem.
EPC4AI FUEL FILTER OUTLET PRESSURE
Remove air bleed orifice hose from fuel filter

fitting.
@) ~ GO to IEPC4CI.
Install adapter 5651 with Pressure Test Kit 014-

00761 or equivalent. (Refer to Pressure Test Kit ~'. GO to IEPC4BI.
Hook-Up Illustration.)
Run engine at 3,300 rpm, with no load.
- .
Record pressure reading. On dual tank vehicles,
check both tanks. ~
Pressure should be minimum of 1 psi at 3,300

rpm.
~
EPC4B I FUEL SUPPLY PUMP OUTLET PRESSURE
Remove vacuum purge valve from fuel filter

adapter.
@) ~ REPLACE fuel filter
and REPEAT Test Step
Install adapter 3019 and Pressure Test Kit 014- IEPC4A\.
0076-1 or equivalent. (Refer to Pressure Test Kit
Hook-Up Illustration.)
NOTE: Make sure clamp is closed on sampling
~ ~ GO to IEPC4CI.
hose.
Leave adapter from Test Step EPC4A installed
and cap end.
Run engine at idle, no ,load.
Record pressure reading. On dual tank vehicles,
check both tanks.
Pressure should be minimum of 2 psi at idle.

ALL RIGHTS RESERVED
Pinpoint
Test
EPC4CI FUEL PUMP CAPACITY
Position end of sample hose on adapter 3019 in Pressure and ~ GO to IEPcsl .

a clear, one quart, graduated fuel container. volume OK
Follow procedures for Test Step IEPC4B I and
open clamp on sample hose, allowing fuel to flow Pressure OK ~ GO to IEPC401.
into fuel container, for 30 seconds. Volume Not OK
Record volume. On dual tank vehicles, check both

tanks. Volume OK ~ REPLACE fuel supply
Pressure Not pump and REPEAT
Volume should be a minimum of on~ pint in 30 OK Test Step IEPC4A I.
seconds at idle, no load.
Pressure and ~ GO to I EPC401.
Volume Not OK
EPC4DI CHECK RESTRICTION AT FUEL SUPPLY PUMP
Connect fuel return line removed in Test Step GO to IEPC4AI.

IEPC4AI.
Install adapter 5632 and Pressure Test Kit to fuel SERVICE or REPLACE
supply pump inlet. restricted chassis fuel
line(s). Refer to Shop
With rear wheels off the ground and transmission Manual, Section 24-50.
in NEUTRAL or PARK, run engine at 3,300 rpm. REPEAT Test Step
IEPC4AI. .
Record vacuum reading. On dual tank vehicles,
check both tanks.
Vacuum should be less than 6 in-Hg.
EPcsl CHECK FUEL RETURN PRESSURE
Remove fuel return line at junction fitting at left

rear of engine.
~ GO to IEPC61.
Install adapter 5663 and Pressure Test Kit 014-

00761, or equivalent.
~~ SERVICE or REPLACE
fuel return line(s) as
necessary. REFER to
Run engine at 3,300 rpm, n6 load, transmission in Shop Manual, Section
NEUTRAL or PARK. 24-50. REPEAT Test
Record pressure reading. On dual tank vehicles, Step IEPcsl .
check both tanks.
Maximum pressure should not exceed 2 psi at
3,300 rpm.
NOTE: Fuel return hose removed in IEPC4A I
must be connected for this test.

ALL RIGHTS RESERVED
Diesel Diagnosis ...... 7.3L Engine 2053
Pinpoint
Engine ~erf~rmance Diagnosis' EPC
Test
TEST STEP RESULT ~ ACTION TO ! AKE

EPC61 CHECK AIR INTAKE RESTRICTION
Remove cap on air cleaner test port and install More than ,2 ~ REMOVE adapter.
adapter 5650 and Pressure Test Kit 014-00761, inches H20 but INSTALL cap on air
or equi.valent. less than 25 cleaner port. GO t6
inches H2O IEPC71.
Run engine a~. 3,300 rpm, no load.
Record restriction reading. 25 inches H2O ~ REPLACE filter element
or more and CHECK intake
Restriction should not exceed 25 inches of H2O. system for blockage.
REPEAT Test Step
IEPC61.
Less than 2 ~ CORRECT restriction in

inches H2O fitting on air cleaner
test port. REPEAT Test
Step IEPC61 .
EPC71 CHECK INJECTION PUMP TRANSFER

PRESSURE
Remove screw from transfer pump pressure port @) ~ GO to IEPCel.

cover.
Install Tool T83T-9000-A or equivalent through
cover and O-ring and into port. Install adapter
fh ~ REPLACE injection
pum~ (REFER to Shop
Manual, Section 22-08.)
5650 and Pressure Test Kit 014-00761 or
If performance problem
equivalent. still exists after
Fittings must be tight and not leaking. installing new pump,
CHECK and ADJUST
Run engine at 3,300 rpm, no load, with injection pump dynamic
transmission in NEUTRAL. timing. (REFER to
adjustments in this
Record pressure reading. Section.) If performance
. Pressure should be 90 to 110 PSI. problem still exists
after aiiustinR timing,
GO to EPCe .
",

ALL RIGHTS RESERVED
20-54 Diesel Diagnosis ..... 7.3L Engine
Pinpoint
Test
EPce ACCELERATOR LINKAGE ADJUSTMENT
With engine off, check that throttle lever contacts GO to IEPC91.

injection pump stop at full accelerator pedal
depression. Full throttle screw is not adjustable. ADJUSTor SERVICE
Tampering may cause injection pump damage. vehicle throttle linkage
as necessary. (Refer to
24-60.) GO to IEPC91 .
FULL
THROTILE
POSITION
EPC9 CHECK ENGINE IDLE SPEED
Check engine idle speed as described under GO to IEPC101.

Adjustments in this Section.
Bring engine up to normal operating temperature. ADJUST as necessary.
GO to IEPC101.
Idle speed is measured with manual transmission
in NEUTRAL and automatic transmission in
DRIVE.
Idle speed is shown on Vehicle Emission Control
Information (VECI) decal.

ALL RIGHTS RESERVED
Pinpoint
Test
I
EPC10 DYNAMIC INJECTION PUMP TIMING**
Install Dynamic Timing Meter and check injection B is more than ~ GO to IEPC 11 I.
pump timing. (Refer to Dynamic Injection Pump 1 advanced
Timing.) Measure at 2,000 rpm, no load. from A, and A
is within 2.
**Engine must be at normal operating temperature.
Record dynamic timing in Box A, Step 10 of the B is more than ~ ADJUST timing.
7.3L Engine Performa~ce Chart. 1 advanced (REFER to Shop
from A, and A Manual, Section 22-08
Apply + 12 volt battery power to the injection . is not within and adjustments.) If
pump timing advance solenoid and record dynamic 2. performance problem
timing in Box B, Step 10 of the 7.3L Engine still exists after
Performance Chart. tdjUstinp timing, GO to
EPC11. .
B is less than ~ REPLACE fuel. injection

1 advanced pump and REPEAT
from A. I EPC101.
I
EPC11 CHECK INJECTION NOZZLES AND INLET
LINES
NOTE: Perform this check only if engine has an Lines and ~ GO To IEPC121.
obvious combustion knock or miss. nozzles OK
Check injection nozzle inlet lines for kinks or

restriction. (Refer to Shop Manual, Section 22-08.) Lines and/or ~ REPLACE damaged
nozzles not OK injection nozzle fuel
Test injection nozzles as described in this Section. inlet lines. (REFER to
NOTE: Warranty claims for Injection nozzles will 22-08.)
not be accepted unless the completed
Engine Performance chart Is submitted REPLACE injection
with the returned parts. noziles as described in
this Section and Shop
If performance problem
still exists, GO to
IEPC121.

ALL RIGHTS RESERVED
Pinpoint
Test
EPC121 CRANKCASE PRESSURE TEST
Remove crankcase depression regulator valve and

securely plug opening to prevent blow-by. (Refer
~ REPLACE injection
pump, and CHECK and
to Shop Manual, Section 22-08.) ADJUST timing.
(R EFER to Shop
Remove oil filler cap and install adapter 5631, Manual, Section 22-08
and Pressure Test Kit 014-00761, or equivalent. and Adjustments in this
(Refer to Pressure Test Kit Hook-Up illustration.) Section.)
Ensure dipstick is seated in dipstick tube.
Run engine at 3,300 rpm no load, with
transmission in NEUTRAL.
fh ~ Problem is internal to
the engine. (REFER to
22-08.)
Record press~re reading.
Pressure should not exceed 6 inches H2 0 at
3,300 rpm.
NOTE: Warranty claims for injection pumps will
not be accepted unless all tamper-
resistant seals are intact and the
completed Engine Performance Chart is
submitted with the returned parts.

ALL RIGHTS RESERVED
Injection Nozzle Testing
Where ideal conditions of good combustion, specified engine temperature control, and
absolutely clean fuel prevail, nozzles require little attention. Nozzle trouble is usually indicated
by one or more of the following symptoms:
Smoky exhaust (black)
Loss of power
Misfiring
Increased fuel consumption
Combustion Knock
Engine Overheating
When faulty nozzle operation is suspected on an engine that is misfiring or puffing black
smoke, a simple test can be made to determine which cylinder(s) is causing the problem.
Run the engine at the rpm which makes the problem most pronounced.
Momentarily loosen the high-pressure fuel inlet line connection on one nozzle assembly one-
half to one turn. Then, tighten connection to specification.
Check each cylinder in the same manner;
If one nozzle is found where loosening makes no difference in the misfiring, or the' puffing
black 'smoke stops, that nozzle should be tested. Test only the suspect nozzle(s).
Remove suspect nozzles as outlined in Shop Manual, Section 22-08. After removing nozzle(s)
from the engine, the Injection Nozzle Test should be performed. This test will provide valuable
information regarding the condition of the nozzle(s). A clean workbench, clean washing fluid
containers, clean tools, and clean hands are all essential to produce satisfactory results.
NOTE: It is advisable to test the nozzles before cleaning them.
Figure 27 shows the Rotunda Injection Nozzle Tester, 014-00300 or equivalent, used for this
test.
NOZZLE
INJECTION
TESTER A8836-8
Figure 27 Injection Nozzle Tester. 014-00300

ALL RIGHTS RESERVED
NOTE: Perform this check only if engine has an obvious combustion knock or miss.
1. Prepare stand for making tests. Fill stand reservoir with clean Calibration Fluid. Open
tester valve slightly and operate tester handle to expel air from tester and outlet pipe.
Operate tester until solid fluid (without air bubbles) flows from end of outlet pipe. Close
tester valve.
2. Connect injection nozzle to test stand. Care should be taken to avoid cross-threading.
Tighten connector nut securely with end wrench. Nozzle Adapter which is supplied with
tester 014-00300 has RH thread to nozzle assembly and LH thread to tester piping.
3. Bleed air from nozzle. Open stand valve and operate tester handle for 8 to 10 quick
strokes to expel (bleed) air from injection nozzle. Fluid should discharge from the spray
hole in nozzle tip.
I WARNING I
ALWAYS WEAR APPROVED SAFETY GLASSES WHEN OPERATING THE TESTER.
VOLATILE LIQUIDS CAN BE EXTREMELY FLAMMABLE WHEN VAPORIZED. AVOID
ANY CONDITIONS (SPARKS, OPEN FLAMES, LIT CIGARETTES, ETC.) WHICH MIGHT
IGNITE THE FLUID USED DURING THE TEST PROCEDURE. THE ONLY LIQUID
APPROVED FOR USE IN THIS TESTER IS SAE CALIBRATION NO. 208629, OR
EQUIVALENT CALIBRATION FLUID (SAE J968D OR ISO 4113).
WHEN A NOZZLE IS BEING TESTED OR IS IN OPERATION, KEEP HANDS AND

OTHER PARTS OF THE BODY AWAY FROM THE NOZZLE. THE LIQUID DISCHARGE
LEAVES THE NOZZLE TIP WITH SUFFICIENT FORCE TO PENETRATE THE SKIN AND
CAUSE SERIOUS INJURY. THE NOZZLE TIP SHOULD BE ENCLOSED IN A
TRANSPARENT RECEPTACLE IF AVAILABLE.
4. Check nozzle opening pressure. Close pump valve, and operate pump handle in slow even
strokes to bring system up to pressure. Record highest pressure reached before nozzle
opens. Repeat operation, increasing handle speed if necessary to establish consistant
readings. Refer to Fig. 28 for nozzle opening pressures.
NOTE: Disregard tip leakage during this test.
NOTE: Spray pattern testing is not reqUired.
CD CALIBRATION CODE: 468J-ROO AND 468XROD.

BE SURE TO USE INJECTORS WITH STAMPED
CODE "B" OR "BB"
Figure 28 Nozzle Opening Pressure

ALL RIGHTS RESERVED
5. Check for tip leakage. Blow nozzle tip dry using filtered compressed air. Operate test
pump to maintain pressure at about 1378 kPa (200 psi) below the opening pressure
obtained in Test 1. Wetting of the nozzle tip is acceptable as long as a drop does not
fall, within five seconds (Fig. 29).
NOTE: Make sure that any accumulation at the nozzle tip is not due to test fluid leaking
down the outside of' the nozzle body from the return openings. If questionable,
wrap a shop cloth around the nozzle body to prevent fluid leaking down the
outside of the nozzle body from reaching the tip.
DROPLET
FALLS
BEFORE
5 SECONDS
,~
ACCEPTABLE ACCEPTABLE UNACCEPTABLE

A9503-8
Figure 29 Nozzle Leakage Patterns

6. After testing is completed, make sure to open the pump valve to release the buitt up
pressure prior to removing the nozzle from the tester. When nozzle is removed, cap the
nozzle tip and inlet until installed back in engine.
NOTE: If nozzle passes the nozzle opening pressure and tip leakage tests, it is suitable
for further service in the engine.
NOTE: Nozzles showing leakage at nozzle tip spray hole or opening pressure below the
minimum permissible limit, are damaged or worn and must be replaced, if within
warranty coverage. Servicing the nozzle(s) (disassemble, clean and rebuild)
instead of replacement to correct nozzle tip leakage or low opening pressure is
only permissible beyond the warranty 'period if so desired.
NOTE: Warranty claims for replacement of the nozzle(s) will not be accepted unless the
completed Engine Performance (Diagnostic) Chart is submitted with the returned
part(s).

ALL RIGHTS RESERVED
INTRODUCTION
Most threaded fasteners are covered by specifications that define .required mechanical properties,
such as tensile strength, yield strength, proof load and hardness. These specifications are carefully
considered in initial selection of fasteners for a given application. To assure continued satisfactory
vehicle performance, replacement fasteners'used should be of the correct strength, as well as the
correct nominal diameter, thread pitch, length, and finish.
Most original equipment fasteners (English system or Metric) are identified with markings or
numbers indicating the strength of the fastener: These markings are described in the pages that
follow. Attention to these markings is important in assuring that the proper replacement fasteners
are used. .
Further, some metric fasteners, especially nuts, are colored blue. This metric blue identification 'is in
most cases a temporary aid for production start-up, and color will generally revert to normal black or
bright after start-up. .
English system and metric system fasteners'are available through your Ford Parts and Service opera-
tion.
NOMENCLATURE FOR BOLTS

(ENGLISH) INCH SYSTEM METRIC SYSTEM
Bo~t, 1/2-13,xl . Bolt M12-1. 75x25
G-Grade Marking P- Property. Class *

(bolt strength) (bolt strength)
L- Length, (inches)* * L- Length (millimeters)* *
T- Thread Pitch T- Thread Pitch (thread width
(thread/inch) crest to' crest mm)
D- Nominal Diameter D- Nominal Diameter
(inches) (millimeters)
*The property class is an Arabic numeral distinguishable from the slash SAE English grade system.
* *The length of all bolts is measured from the underside of the head to the end.

ALL RIGHTS RESERVED
BOLT STRENGTH IDENTIFICATION
(ENGLISH) INCH SYSTEM
English (Inch) bolts-Identification marks correspond to bolt strength-increasing number of

slashes represent increasing strength.
METRIC SYSTEM
Metric bolts-Identification class numbers correspond to bolt strength-increasing numbers repre-

sent increasing strength. Common metric fastener bolt strength property are 9.8 and 10.9 with the
class identification embossed on the bolt head.
HEX NUT STRENGTH IDENTIFICATION

(ENGLISH) INCH SYSTEM METRIC SYSTEM
Grade Hex Nut Hex Nut Class Hex Nut Hex Nut
Grade 5 Grade 8 Property Property
Class 9 Class 10
Identification Identification
@ ~
~ @ @
3 Dots 6 Dots Arabic 9 Arabic 10
Increasing dots represent increasing strength. May also have blue finish or paint daub on hex flat.
Increasing numbers represent increasing strength.
Ol"HER TYPES O~ t>ARTS

Metric identification schemes vary by type of part, most often a variation of that used of bolts and
nuts. Note that many types of English and metric fasteners carry no special identification if they are
otherwise unique.
-Stamped U-Nuts @
CLASS CLASS CLASS
10.9 9.8 8.8
-Studs, Large studs may carry the property class

-Tapping, thread forming and certain other case number. Smaller studs use a geometric code on
hardened screws the end.
2

ALL RIGHTS RESERVED
ENGLISH METRIC CONVERSION
Description I
Multiply By For Metric Equivalent
ACCELERATION Foot/sec 2
0.304 8 metre/sec 2 (m/s 2 )
Inch/sec 2 0.0254 metrejsec 2
TORQUE Pound-inch 0.11298 newton-metres (N'm)
Poul1d-foot .1.355 8 newton-metres
POWER horsepower 0.746 kilowatts (kw)
PRESSURE or STRESS inches of water 0.2488 kilopascals (kPa)
pounds/sq. in. 6.895 kilopascals (kPa)
pounds/sq. in. 14.5 bar
EN ERGY or WORK BTU 1 055. joules (J)
foot-pound 1.355 8 joules (J)
kilowatt-hour 3 600 000. joules (J = one W's)
or 3:6 x 106
LIGHT - foot candle 10.76 lumens/metre 2 (Im/m 2 )
FUEL PERFORMANCE miles/gal 0.425 1 kilometres/litre (km/I)
gal/mile 2.352 7 litres/kilometre (I/km)
VELOCITY miles/hour 1.609 3 ki lometres/hr. (km/h)
LENGTH inch. 25.4 millimetres (mm)
foot 0.3048 metres (m)
yard 0.914 4 metres (m)
mile 1.609 ki lometres (km)
AREA inch 2 645.2 millimetres 2 (mm 2 )
t
6.45 centimetres 2 (cm 2 )
fooF 0.092 9 metres 2 (m 2 )
yard 2 0.836 1 metres 2
VOLUME inch 3 16 387. mm 3
inch 3 16.387 cm 3
quart 0.016 4 litres (1)
quart 0.946 4 litres
gallon 3.7854 litres
yard 3 0.7646 : metres 3 (m 3 )
MASS pou~d 0.453 6 kilograms (kg)
ton 907.18 kilograms (kg)
ton 0.90718 tonne
FORCE kilogram 9.807 newtons (N)
ounce 0.2780 newtons
pound 4.448 newtons
TEMPERATURE degree farenheit 0.556 (OF -32) degree Celsius (OC)

ALL RIGHTS RESERVED
JJ1ETRICS
DECIMAL AND METRIC EQUIVALENTS
Fractions Decimal Inch Metric mm Fractions Decimal Inch Metric mm

1/64 .015625 .397 33/64 .515625 13.097
1/32 . .03125 .794 17/32 .53125 13.494
3/64 .046875 1.191 35/64 .546875 13.891
1/16 .0625 1.588 9/16 .5625 14.288
5/64 .078125 1.984 . 37/64 .578125 14.684
3/32 .09375 2.381 19/32 .59375 15.081
7/64 .109375 2.778 39/64 .609375 15.478
1/8 .125 3.175 5/8 .625 15.875
9/64 .140625 3.572 41/64 .640625 16.272
5/32 .15625 3.969 21/32 .65625 16.669
11/64 .171875 4.366 43/64 .671875 17.066
3/16 .1875 4.763 11/16 .6875 17.463
13/64 .203125 5.159 45/64 .703125 17.859
7/32 .21875 5.556 23/32 .71875 18.256
15/64 .234375 5.953 47/64 .734375 18.653
1/4 .250 6.35 3/4 .750 19.05
17/64 .265625 6.747 49/64 .765625 19.447
9/32 .28125 7.144 25/32 .78125 19.844
19/64 .296875 7.54 51/64 .796875 20.241
5/16 .3125 7.938 13/16 .8125 20.638
21/64 .328125 8.334 53/64 .828125 21.034
11/32 .34375 8.731 27/32 .84375 21.431
23/64 .359375 9.128 55/64 .859375 21.828
3/8 .375 9.525 7/8 .875 22.225
25/64 .390625 9.922 57/64 .890625 22.622
13/32 .40625 10.319 29/32 .90625 23.019
27/64 .421875 10.716 59/64 .921875 23.416
7/16 .4375 11.113 15/16 .9375 23.813
29/64 .453125 11.509 61/64 .953125 24.209
15/32 .46875 11.906 31/32 .96875 24.606
31/64 .484375 12.303 63/64 .984375 25.003
1/2 .500 12.7 1 1.00 25.4

ALL RIGHTS RESERVED
_ _ _ _ _ _"~ETRICS
TORQUE CONVERSION
NEWTON METRES POUND-FEET POUND-FEET NEWTON METRES

(N'm) (LB-FT) ( LB-FT) (N-m)
1 0.7376 1 1.356
2 1.5 2 2.7
3 2.2 3 4.0
4 3.0 4 5.4
5 3.7 5 6.8
6 4.4 6 8.1
7 5.2 7 9.5
8 5.9 8 10.8
9 6.6 9 12.2
10 7.4 10 13.6
15 11.1 15 20.3
20 14.8 20 27.1
25 18.4 25 33.9
30 22.1 30 40.7
35 25.8 35 47.5
40 29.5 40 54.2
50 36.9 45 61.0
60 44.3 50 67.8
70 51.6 55 74.6
80 59.0 60 81.4
90 66.4 65 88.1
100 73.8 70 94.9
110 81.1 75 101.7
120 88.5 80 108.5
130 95.9 90 122.0
140 103.3 100 135.6
150 110.6 110 149.1
160 118.0 120 162.7
170 125.4 130 176.3
180 132.8 140 189.8
190 140.1 150 203.4
200 147.5 160 216.9
225 166.0 170 230.5
250 184.4 180 244.0
"'

ALL RIGHTS RESERVED
We Want To Hear From You!
Do you have any suggestions for improving this publication?
FOR EXAMPLE...
Did you find any errors?

If yes; Manual -:--_ Volume Page_'__
,Were any subjects not covered?

If yes; Please describe.
Were any sections confusing or hard to understand?

If yes; Manual Volume Page _
Please co~ment:
Could you quickly find what you need? Yes No
Suggestions:
Tell us who you are:

Name ---,- _
Address _
Position _ Company. _
It is most helpful if you would enclose a copy of each page, marked with your
suggestions.

ALL RIGHTS RESERVED

1990 Ford Truck Emmisions Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1990 Ford Truck Emmisions Manual

Uploaded by

Copyright:

Available Formats

Important Safety Notice

APpropriate service methods and proper repair procedures are essential

Notes, cautions, and warnings

DAVE GRAHAM INC. 2012

Copyright 1989, Ford Motor Company

DAVE GRAHAM INC. 2012

Mark VII Body, Chassis, Electrical, POwertraln,

Thunderbird I Cougar Body, Chassis, "Electrical, POwertraln,

Mustang Body, Chassis, Electrical, Powertrain,

Tempo I Topaz, Escort Body, Chassis, Electrical, Powertrain,

Taurus/Sable Body, Chassis, Electrical, Powertraln,

Continental Body, Chassis, Electrical, Powertraln,

All Models pre-Delivery

NAAO car & Truck Models Engine / Emissions Diagnosis

Non-NAAO Cars Non-NAAO Engine I Emissions Diagnosis

DAVE GRAHAM INC. 2012

vehicle Lines content

Econollne, F-serles, Bronco BOdY/ Chassis / Electrical

Econonne, F-Serles, Bronco Engine

Medium/Heavy Duty B-, C, F-600 Body / Chassis / Electrical! Engine

Aerostar, Ranger, Bronco II (1 Of 2) Engine / Chassis

Aerostar. Ranger, Bronco II (2 Of 2) BOdy/ Electrical

All Truck Series and car Models pre-Delivery (Volume F)

All NAAO car and Truck Models Engine / Emissions Diagnosis

DAVE GRAHAM INC. 2012

Modified Manual sections

~ew or Modified Pinpoint Tests

DAVE GRAHAM INC. 2012

DAVE GRAHAM INC. 2012

Refer to Section 1, Emission Control

DAVE GRAHAM INC. 2012

SECTIONS 3, 4, 5, 6, 7, COMPLEMENTARY INFORMATION

I Verify Repair 1 Truck*

- Electrical and Vacuum

DAVE GRAHAM INC. 2012

DAVE GRAHAM INC. 2012

4EAT: 4-Speed Electronic Automatic ATDC: After Top Dead Center.

ACCS: AIC Cycling Switch. BATT: Battery

ACl: Automatic Adjustable Shock BOB: (Breakout Box) An EEC-IV test

AOD: Automatic Overdrive. CANP: Canister Purge solenoid or its

DAVE GRAHAM INC. 2012

CFI: Central Fuel Injection. A computer DV TW: Delay Valve Two-Way.

DAVE GRAHAM INC. 2012

FLC: Fluid Lock-Up Converter. HIC: Hot Idle Compensator.

DAVE GRAHAM INC. 2012

HlOS: Hardware Limited Operation KOER: Key On Engine Running Self-Test

DAVE GRAHAM INC. 2012

PIP: Profile Ignition Pickup. A "hall effect" SC: Super Charged.

DAVE GRAHAM INC. 2012

DAVE GRAHAM INC. 2012

VRESER: Vacuum Reservoir. VSS: Vehicle Speed Sensor or its signal

DAVE GRAHAM INC. 2012

Vehicle Emission Control Information Decal 1-1

Vehicle Emission Control Information Decal Location 1-2

Emission Control Application:

Light Truck 1-4

Medium/Heavy Truck 1-5

DAVE GRAHAM INC. 2012

Vehicle Emission Control Information Decal

FORD MOTOR COMPANY 1IIlCUUM HOlE MlUTINQ

THIS YEHICU CO.... O". . TO U.S. EPA /lIIIO CALIFORNIA IttGULATIOItS

Figure 1 Typical Vehicle Emission Control Information Decal

DAVE GRAHAM INC. 2012

Vehicle Emission Control Information Decal Location